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Service Department. Technical Information

Service
List of Workshop Manual Repair Groups
Repair Group
00 - Technical data
10 - Removing and installing engine
13 - Crankshaft group
15 - Cylinder head, valve gear
17 - Lubrication
19 - Cooling
20 - Fuel supply system agen
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23 - Mixture preparation - injection ut
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26 - Exhaust system s
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28 - Glow plug system
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Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.
All rights reserved.

No reproduction without prior agreement from publisher.
Copyright © 2015 Volkswagen AG, Wolfsburg D3E801CBF41

Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤
4-cylinder diesel engine (1.9 l engine) - Edition 12.2013
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Engine number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Engine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.1 Safety precautions when working on fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.2 Safety precautions for when using test and measuring equipment during a road test . . . . 4
2.3 Safety precautions when working on cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3 General repair notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.1 Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.2 Foreign objects in engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
10 - Removing and installing

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1.3 Removing engine (Passat) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
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1.4 Securing engine to assembly stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
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1.5 Notes on installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
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1.6 Assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
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13 - Crankshaft group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
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1 Dismantling and assembling engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

1.1 Assembly overview - poly V-belt drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . t to the co 29
1.2 Assembly overview - toothed belt drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
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1.3 Removing and installing engine support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

1.4 Assembly overview - crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
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2 Removing and installing sealing flange and flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

2.1 Assembly overview - sealing flanges and flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
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2.2 Removing and installing dual-mass flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

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2.3 Renewing crankshaft oil seal - pulley end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

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2.4 Removing and installing sealing flange - pulley end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

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2.5 Renewing crankshaft sealing flange - flywheel end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

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3 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
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3.1 Assembly overview - crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

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4 Pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
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4.1 Assembly overview - pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
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4.2 Separating new conrod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
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4.3 Checking piston projection at TDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
4.4 Piston and cylinder dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
4.5 Piston rings, cylinder bore and piston installation position . . . . . . . . . . . . . . . . . . . . . . . . . . 61
15 - Cylinder head, valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

1 Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
1.1 Assembly overview - cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
1.2 Removing and installing cylinder head cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
1.3 Removing, installing and tensioning toothed belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
1.4 Removing and installing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
1.5 Checking compression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
2 Valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
2.1 Assembly overview - valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
2.2 Checking valve guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
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2.3 Renewing valve stem seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

2.4 Removing and installing camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
2.5 Removing and installing camshaft oil seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
17 - Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
1 Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
1.1 Oil capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
1.2 Checking engine oil level, observing differences in dip sticks . . . . . . . . . . . . . . . . . . . . . . 108
2 Parts of lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
2.1 Assembly overview - oil pump, sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
2.2 Removing and installing oil sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
3 Oil filter bracket, oil pressure, engine oil cooler and oil supply line . . . . . . . . . . . . . . . . . . 115
3.1 Assembly overview - oil filter bracket and engine oil cooler . . . . . . . . . . . . . . . . . . . . . . . . 115
3.2 Checking oil pressure and oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
3.3 Assembly overview - oil supply line to turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
3.4 Removing and installing oil supply line to turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
19 - Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
1 Parts of cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
1.1 Coolant hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
1.2 Draining and filling coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
1.3 Coolant pump, regulation of cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
1.4 Parts of cooling system, body side (radiator with two fans) . . . . . . . . . . . . . . . . . . . . . . . . 133
1.5 Assembly overview - parts of cooling system, body side (radiator with one fan) . . . . . . . . 135
1.6 Removing and installing fan support with fans (Golf, Golf Plus, Touran) . . . . . . . . . . . . . .
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1.11 Checking engine oil cooler for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142

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20 - Fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144

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1 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144

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1.1 Safety precautions when working on fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . 144

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2 Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145

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2.1 Rules for cleanliness when working on fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . 145
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3 Parts of fuel supply system (Golf, Golf Plus) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146

3.1 Fuel tank, vehicles with front-wheel drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
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3.2 Fuel tank, vehicles with four-wheel drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149

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3.3 Emptying fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156

3.4 Removing and installing fuel delivery unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
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3.5 Removing and installing fuel gauge sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159

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3.6 Checking fuel pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160

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3.7 Assembly overview - fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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3.8 Removing and installing fuel cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166

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4 Parts of fuel supply system (Touran) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168

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4.1 Assembly overview - fuel tank with attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168

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4.2 Emptying fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
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4.3 Removing and installing fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
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4.4 Assembly overview - fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
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4.6 Removing and installing fuel delivery unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
4.7 Removing and installing fuel gauge sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
5 Parts of fuel supply system (Passat) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
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5.1 Fuel tank, vehicles with front-wheel drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184

5.2 Emptying fuel tank, vehicles with front-wheel drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
5.4 Assembly overview - fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
6 Accelerator mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
6.1 Assembly overview - accelerator mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
7 Tandem pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
7.1 Checking tandem pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
7.2 Removing and installing tandem pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
21 - Turbocharging/supercharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
1 Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
1.1 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
1.2 Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
1.3 Assembly overview - turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
1.4 Removing and installing turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
1.5 Vacuum hose schematic diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226
2 Charge air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229
2.1 Assembly overview - parts of charge air cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229
2.2 Hose connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232
2.3 Checking charge air system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233
23 - Mixture preparation - injection . . . . . . . . . . . . . . g.e.n A. G.. .Vo.lk.sw. a.ge. n.A.G.d . . . . . . . . . . . . . 236

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1.1 Safety precautions . . . . . . . . . . . . . . . o.ris. e. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .an.te.e. . . . . . 236
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1.3 Removing and installing pre-wired wiring harness for unit injectors and glow plugs . . . . . . 237
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1.4 Assembly overview - unit injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240
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1.5 Removing and installing unit injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241
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1.6 Adjusting non-contact gap of unit injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243
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1.7 Removing and installing O-rings for unit injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244
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2 Air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246
spec
2.1 Assembly overview - air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246
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3 Intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247
3.1 Assembly overview - intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247
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4 Engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251
4.1 Reading and deleting engine control unit event memory . . . . . . . . . . . . . . . . . . . . . . . . . . 251
l purpos
4.2 Adapting functions and components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 252

4.3 Removing and installing engine control unit (Golf) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253
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4.4 Removing and installing anti-theft engine control unit (Golf) . . . . . . . . . . . . . . . . . . . . . . . . 253
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4.5 Removing and installing engine control unit (Golf Plus) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 256
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4.6 Removing and installing anti-theft engine control unit (Golf Plus) . . . . . . . . . . . . . . . . . . . . 256
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4.7 Removing and installing engine control unit (Touran) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258

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4.8 Removing and installing anti-theft engine control unit (Touran) . . . . . . . . . . . . . . . . . . . . . . 259
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4.9 Engine control unit (Passat) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .yi

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26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267
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1 Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267
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1.1 Assembly overview - front exhaust pipe with catalytic converter . . . . . . . . . . . . . . . . . . . . 267
1.2 Assembly overview - silencer with mountings (vehicles with front wheel drive) . . . . . . . . . . 268
1.3 Assembly overview - silencers (Passat) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270
1.4 Assembly overview - silencer with mountings (vehicles with four-wheel drive) . . . . . . . . . . 271
1.5 Aligning exhaust system free of stress . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272
2 Emission control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273
Contents iii
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Golf 2004 ➤ , Golf Plus 2005 ➤ yV
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4-cylinder diesel engine (1.9ir se l engine) - Edition 12.2013
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2.1 ss
Assembly overview - front exhaust pipe with particulate filter . . . . . . . . . . . . . . . . . . . . . . 273
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3 Exhaust gas recirculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276
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3.1 Assembly overview - parts of exhaust gas recirculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276
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3.2 Checking mechanical exhaust gas recirculation valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280
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28 - Glow plug system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 281
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1 Glow plug system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 281
urposes, in part or in wh
t to the co
1.1 Removing, installing and checking glow plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 281
1.2 Characteristics of ceramic glow plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282
1.3 Removing, installing and checking ceramic glow plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282
rrectne
1.4 Removing and installing engine speed sender G28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 284
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iv Contents
00 – Technical data AG. Volkswagen AG d

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1 Technical data orised ara
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(VRL006354; Edition 12.2013)
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Engine number ⇒ “1.1 Engine number”, page 1
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Engine data ⇒ “1.2 Engine data”, page 1
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1.1 Engine number
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The engine number (“code letters” and “serial number”) can be
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found at the joint between engine and gearbox.
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Additionally there is a sticker on the toothed belt guard with “en‐
gine code” and “serial number”.
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The engine code is also included on the vehicle data sticker.
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1.2 Engine data
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Edition 05.2012 Version 9.0

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AVQ BJB BKC BRU BLS BXE BXF BXJ
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Golf/Golf Plus produc‐ cted 10.03 ► 10.03 ► 04.04 ► 02.06 ► 03.06 03.06 11.07
agen
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tion
Passat 05.05► 03.06 12.04►
production ►
Touran 02.03 ► 10.03 ► 10.04 02.06 ► 03.06 03.06 ► 10.06 ►
production ►
Emissions fulfil EU4 EU3 EU4 EU4 EU4 EU4 EU4 EU4
standard standard standard stand‐ stand‐ stand‐ stand‐ standard
ard ard ard ard
Capacity l 1.9 1.9 1.9 1.9 1.9 1.9 1.9 1.9
Output kW at rpm 74/4000 77/ 77/ 66/ 77/ 77/ 66/ 66/
4000 4000 4000 4000 4000 4000 4000
Torque Nm at 250/1900 250/ 250/ 210/ 250/ 250/ 210/ 210/
rpm 1900 1900 1800 ... 1900 1900 1800 1800 ...
2500 2500
Bore ∅ mm 79.5 79.5 79.5 79.5 79.5 79.5 79.5 79.5
Stroke mm 95.5 95.5 95.5 95.5 95.5 95.5 95.5 95.5
Valves per cylinder 2 2 2 2 2 2 2 2
Compression ratio 19.0 19.0 19.0 19.0 18.5 18.5 19.0 19.0
Fuel according DIN EN DIN EN DIN EN DIN EN DIN EN DIN DIN EN DIN EN
to 590 590 590 590 590 EN 590 590
590
Firing or‐ 1-3-4-2 1-3-4-2 1-3-4-2 1-3-4-2 1-3-4-2 1-3-4- 1-3-4-2 1-3-4-2
der 2
Catalytic yes yes yes yes yes yes yes yes
converter
Exhaust yes yes yes yes yes yes yes yes
gas recir‐
culation
1. Technical data 1
AVQ BJB BKC BRU BLS BXE BXF BXJ

Turbo‐ yes yes yes yes yes yes yes yes
charging/
super‐
charging
Charge air yes yes yes yes yes yes yes yes
cooler
Particulate no no no no yes no no yes
filter
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2 Rep. gr.00 - Technical data

2 Safety instructions
⇒ “2.1 Safety precautions when working on fuel supply system”,
page 3
⇒ “2.2 Safety precautions for when using test and measuring
equipment during a road test”, page 4
⇒ “2.3 Safety precautions when working on cooling system”, page
4
2.1 Safety precautions when working on

fuel supply system
WARNING
Risk of injury due to highly pressurised fuel.

♦ For safety reasons, the fuse must be removed from the
fuel pump control unit - J538- before the fuel system is
opened if the battery has not been disconnected. Other‐
wise the fuel pump will be activated by the driver door
contact switch.
♦ Wrap a clean cloth around the connection before opening
the fuel system. Then release pressure by carefully loos‐
ening the connection.
♦ Wear protective gloves.
♦ Wear eye protection.
Danger of burning from very hot fuel.
♦ In extreme cases, the temperature of the fuel or the fuel
lines can reach 100 °C after the engine is switched off.
Allow the fuel to cool down before disconnecting the lines
- danger of scalding.
♦ Wear protective gloves. n AG. Volkswagen AG do
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♦ Wear eye protection. d byV
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To prevent injuries to persons and destruction of the injection and
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glow plug system, the following must be noted:

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♦ Always switch off the ignition before connecting or discon‐

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necting electrical wiring of the injection and glow plug system

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or connecting/disconnecting tester cables.

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♦ Wash the engine only with the ignition switched off.

hole
spec
♦ Entries have been stored in the event memory of the engine

es, in part or in w
t to the co
control unit if the engine was started after electrical connectors

had been disconnected: Read event memory in vehicle
self-diagnosis ⇒ Vehicle diagnostic tester .
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Caution
♦ Observe prescribed procedures when disconnecting bat‐

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tery ⇒ Electrical system; Rep. gr. 27 ; Battery; Discon‐

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– Disconnect battery ⇒ Electrical system; Rep. gr. 27 ; Battery;

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Disconnecting and reconnecting battery .

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2.2 Safety precautions for when using test by ara
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and measuring equipment during a road th eo
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Note the following if testers and measuring instruments have to
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be used during a road test:
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♦ Test and measuring instruments must always be secured to
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the rear seat and operated by a second person from this lo‐
hole
cation.
spec
es, in part or in w
♦ If test and measuring instruments are operated from front pas‐
t to the co
senger seat and the vehicle is involved in an accident, there
is a possibility that the person sitting in this seat may receive
serious injuries when the airbag is triggered.
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cooling system
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WARNING
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Hot steam/hot coolant can escape - risk of scalding.
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♦ The cooling system is under pressure when the engine is
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♦ Cover filler cap on expansion tank with a cloth and open C py
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Danger of injury; the radiator fans can run at any time. cted agen
Prote AG.
♦ Disconnect electrical connectors before starting work in

the area of the radiator cowl.
Caution
Danger of overheating due to incorrectly fitted cap.

♦ Tighten cap of coolant expansion tank until it engages.
4 Rep. gr.00 - Technical data

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3 General repair notes
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⇒ “3.1 Rules for cleanliness”, page 5
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⇒ “3.2 Foreign objects in engine”, page 5
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spec
3.1 Rules for cleanliness
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When working on fuel supply and injection system, pay careful
attention to the following rules for cleanliness:
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♦ Before disconnecting, thoroughly clean all unions and adja‐
l purpos
cent areas e.g. with brake cleaner.

♦ Place removed parts on a clean surface and cover. Use only
nform
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lint-free cloths.
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♦ Carefully cover opened components and connections or seal
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if repairs cannot be carried out immediately.
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♦ Install clean components only. Do not remove replacement

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parts from packing until immediately before installing. Do not

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tool boxes etc.).

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♦ When the system is open: Do not work with compressed air. yri
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Do not move vehicle.
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♦ Also ensure that no diesel fuel comes into contact with the
AG.
coolant hoses. Should this occur, the hoses must be cleaned

immediately. Damaged hoses must be renewed.
3.2 Foreign objects in engine
Note
If large quantities of swarf or metal particles (caused, for example,

by partial seizure of the crankshaft or conrod bearings) are found
in the engine oil when performing repairs, clean the oil passages
thoroughly and renew the engine oil cooler in order to prevent
subsequent damage.
3. General repair notes 5

10 – Removing and installing engine

1 Removing and installing engine
⇒ “1.1 Removing engine (Golf, Golf Plus)”, page 6
⇒ “1.2 Removing engine (Touran)”,wapage 11
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⇒ “1.4 Securing engine
au to assembly stand”, page 24
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⇒ “1.5 Notes on installing”, page 25
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⇒ “1.6 Assembly mountings”, page 27
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1.1 Removing engine (Golf, Golf Plus)
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Special tools and workshop
es, in part or in w
equipment required
t to the co
♦ Lifting tackle - 2024 A-
♦ Engine bracket - T10012-
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♦ Support clamp - VW 313-
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♦ Engine and gearbox sup‐

port - VW 540-
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♦ Workshop hoist - V.A.G
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♦ Drip tray - V.A.G 1306-

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6 Rep. gr.10 - Removing and installing engine

4-cylinder diesel
wage engine (1.9 l engine)
e - Edition 12.2013
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♦ Torque wrench - V.A.G utho eo
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♦ Torque wrench - V.A.G
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♦ Engine and gearbox jack -
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V.A.G 1383 A-
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♦ Spring-type clip pliers -
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VAS 5024-
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♦ Stepladder - VAS 5085-
♦ Guide rods - T10093-
rrectne
♦ Cable ties
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Note
♦ Before carrying out further work, disconnect battery earth

strap. First check whether a coded radio is fitted and obtain
anti-theft coding if necessary.
♦ The engine is removed downwards together with the gearbox.
♦ All cable ties which are opened or cut through when engine is
removed must be replaced in the same position when engine
is installed.
1. Removing and installing engine 7

WARNING
When doing any repair work, especially in the engine compart‐

ment, pay attention to the following due to the cramped condi‐
tions:
♦ Route all the various lines (e.g. for fuel, hydraulics, acti‐
vated charcoal filter system, coolant and refrigerant, brake
fluid and vacuum) and electrical wiring in their original po‐
sitions.
♦ Ensure that there is sufficient clearance to all moving or
hot components.
Procedure
– With ignition switched off, disconnect earth strap from battery.
One-piece engine cover
For one-piece engine cover, pull engine cover abruptly upwards
at front and right -arrows A-, then pull forwards out of rear fas‐
tening -arrow B-.
Two-piece engine cover wage

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For two-piece engine cover, first pull outer engine cover abruptlyed by ua
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upwards at -arrows-, then pull inner engine cover abruptly up‐thoris tee
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– Remove plenum chamber bulkhead. ⇒ General body repairs,
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exterior; Rep. gr. 50 ; Bulkhead; Assembly overview - bulk‐
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– Remove air filter housing with air mass meter and connecting
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– Remove bolt -arrow A- and pull air filter housing upwards out
of mounting.
– Remove battery and battery tray.
– Disconnect fuel supply and return lines as well as coolant line
on cylinder head.
WARNING
♦ The fuel and the fuel lines in the fuel system can become
very hot (danger of scalding)!
♦ The fuel system is also under pressure! Before opening
the system, place cloths around the connections. Then
carefully loosen connection to release the pressure!
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– Remove noise insulation ⇒ General body repairs, exterior;
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Rep. gr. 50 ; Assembly overview - Body - front .
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– Bring lock carrier into service position ⇒ General body repairs,
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exterior; Rep. gr. 50 ; Body - front; Lock carrier - service po‐
ot
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– Drain coolant ⇒ page 125 .
spec
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Vehicles with air conditioner
t to the co
Note
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To prevent damage to condenser or to refrigerant lines/hoses,

ensure that the lines and hoses are not stretched, kinked or bent.
nform
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To facilitate removing and installing engine without opening re‐

m
a
frigerant circuit:
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– Remove poly V-belt ⇒ page 30 .

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– Remove air conditioner compressor ⇒ Heating, air condition‐

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– Secure air conditioner compressor to lock carrier so that re‐ yri
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– Remove alternator ⇒ Electrical system; Rep. gr. 27 ; Remov‐
AG.
ing and installing alternator and poly V-belt .

Continuation for all vehicles
– Remove connecting pipes between charge air cooler and en‐
gine.
– Unbolt left and right-hand drive shafts from gearbox ⇒ Run‐
ning gear, axles, steering; Rep. gr. 40 ; Removing and instal‐
ling drive shaft .
– Remove front exhaust pipe ⇒ page 267 .
– Release connector from engine control unit, disconnect con‐
nector.

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– Open all cable guide fasteners -arrows-.
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– Remove wiring harness from cable guide on longitudinal mem‐
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ber and lay to side on engine.
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– Pull off or disconnect all other electrical connections from en‐
h re
ole,
gine and gearbox as necessary and lay to side.
spec
– Separate all connecting, coolant, vacuum and intake hoses
t to the co
from engine.
Vehicles with manual gearbox
rrectne
– Remove slave cylinder for hydraulic clutch. ⇒ 6-speed manual
gearbox 02S; Rep. gr. 30 ; Repairing clutch mechanism; As‐
s
sembly overview - hydraulics .
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– Unbolt selector mechanism from gearbox ⇒ 6-speed manual
form
mer
gearbox 02S; Rep. gr. 34 ; Repairing selector mechanism .
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Vehicles with four-wheel drive:

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– Remove selector mechanism from gearbox ⇒ 6-speed man‐

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ual gearbox 02Q, four-wheel drive; Rep. gr. 34 ; Repairing

i
o
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selector mechanism .
r
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– Separate pressure line for hydraulic clutch control. t. Cop py
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– Remove front propshaft ⇒ Final drive 02D, 0AV; Rep. gr. 39 ; yri
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Assembly overview - repairing propshaft .
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Continuation for all vehicles:
– Unbolt pendulum support -arrows-.

Vehicles with particulate filter
– Remove subframe ⇒ Running gear, axles, steering; Rep. gr.
40 ; Removing and installing subframe .
– Remove right drive shaft ⇒ Running gear, axles, steering;
Rep. gr. 40 ; Removing and installing drive shafts .
– Remove steering rack ⇒ Running gear, axles, steering; Rep.
gr. 48 ; Removing and installing steering rack .
– Insert engine bracket - T10012- in engine and gearbox jack -

V.A.G 1383 A- .
Note
Support pins must be secured to engine bracket - T10012- as

shown.
– Fit engine bracket - T10012- to cylinder block with M10 x 25/

8.8 bolt and tighten to approx. 40 Nm.
– Raise engine and gearbox slightly using engine and gearbox
jack - V.A.G 1383 A- .

– Unbolt assembly mounting on engine side from engine bracket

-arrows-.
Note
To remove securing bolts, use stepladder - VAS 5085- .
– Unbolt assembly mounting on gearbox side from gearbox

bracket -arrows-.
– Carefully lower engine with gearbox.
Note
Engine with gearbox must be guided carefully when lowering to

prevent damage to bodywork.
1.2 Removing engine (Touran)
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11
Prote AG.
1. Removing and installing engine

equipment required
port - VW 540-
1202 A-
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1331-
1332-
♦ Engine and gearbox jack
agen
AG.-Volkswagen AG d
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V.A.G 1383 A-
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Note

strap. Check whether a coded radio is fitted. Obtain anti-theft
coding first if necessary.
is installed.

WARNING

tions:
sitions.
hot components.

– Remove engine cover. To do this, pull engine cover upwards AG. Volkswagen AG d
abruptly at front -arrows A- and then pull forwards out of rear agen oes
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Two-piece engine cover
For two-piece engine cover, first pull outer engine cover abruptly
rrectness of i
upwards at -arrows-, then pull inner engine cover abruptly up‐
wards at -arrows-.
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head .
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of mounting.
on cylinder head.
WARNING
♦ Wear eye and hand protection when performing any type
of repair work on the fuel system!
AG. Volkswagen AG d
– Remove noise insulation. ⇒ General body repairs,olkexterior;
swa
gen oes
not
Rep. gr. 50 ; Body - front; Assembly overviewd.by V gu
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– Bring lock carrier into service position. ⇒ utGeneral
ho body re‐ eo
ra
pairs, exterior; Rep. gr. 50 ; Body - front;
ss a
Lock carrier service c
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– Drain coolant ⇒ page 125
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Vehicles with air conditioner
ility
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Note
spec
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frigerant circuit:
nf
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o
– Remove air conditioner compressor. ⇒ Heating, air condition‐
rm
m
ing; Rep. gr. 87 ; Removing and installing compressor brack‐ atio

m
et .
o
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or c
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– Secure air conditioner compressor to lock carrier so that re‐

t
sd
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frigerant lines/hoses are free of stress.

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– Remove alternator. ⇒ Electrical system; Rep. gr. 27 ; Re‐

ng
t.
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moving and installing alternator with poly V-belt . t. Cop py
rig
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Continuation for all vehicles p by
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– Remove connecting pipes between charge air cooler and en‐ Prote AG.
gine.
– Unbolt left and right-hand drive shafts from gearbox ⇒ Run‐
ning gear, axles, steering; Rep. gr. 40 ; Removing and instal‐
ling drive shaft .
– Remove front exhaust pipe.

– Remove securing nuts -arrows- for engine control unit.

nector.
AG. Volkswagen AG d
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– Open all cable guide fasteners -arrows-.
h re
ole,
spec
– Remove wiring harness from cable guide on longitudinal mem‐
t to the co
– Pull off or disconnect all other electrical connections from en‐
gine and gearbox as necessary and lay to side.
rrectne
– Separate all connecting, coolant, vacuum and intake hoses
from engine.
ss o
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– Remove slave cylinder for hydraulic clutch. ⇒ 6-speed manual
inform
mer
atio
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– Unbolt selector mechanism from gearbox ⇒ 6-speed manual n

c
i
or
n
gearbox 02S; Rep. gr. 34 ; Repairing selector mechanism .
thi
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Vehicles with particulate filter Cop py
t. rig
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– Remove subframe ⇒ Running gear, axles, steering; Rep. gr. p by
o Vo
by c
40 ; Removing and installing subframe .
lksw
cted agen
Prote AG.
Rep. gr. 40 ; Removing and installing drive shafts .
– Remove steering rack ⇒ Running gear, axles, steering; Rep.
gr. 48 ; Removing and installing steering rack .

V.A.G 1383 A- .
Note
Support pins must be secured to engine bracket - T10012- as

shown.
– Fit engine bracket - T10012- to cylinder block with

M10 × 25/ 8.8 bolt and tighten to approx. 40 Nm.
jack - V.A.G 1383 A- .


-arrows-.
Note

bracket -arrows-.
Note

AG. Volkswagen AG d
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1.3 Removing engine (Passat)
a ra
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equipment required
port - VW 540- or engine
and gearbox support - VAS
6095-
olkswagen AG
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♦ Drip tray
ss - V.A.G 1306- or c
drip tray - VAS 6208-
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♦ Torque wrench (5... 50 Nm)

- V.A.G 1331-
♦ Torque wrench (40...
200 Nm) - V.A.G 1332-
♦ Engine and gearbox jack -
V.A.G 1383 A- wagen AG. Volkswagen AG does
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♦ Spring-type
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Not illustrated:
♦ Container for removed parts - V.A.G 1698-

♦ Engine bung set - VAS 6122-
♦ Grease - G 000 100-
♦ Cable ties

Procedure
Note

♦ Leave ignition key in ignition lockgeton Aprevent
G. Volkswsteering
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It is advisable to remove the front wheels before beginning
d
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h eo
ra
platform until the
s splash plates for the brake discs are just
s c
above the floor. This provides the most ergonomic working
ce
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un
pt
position regarding accessibility of engine compartment com‐
an
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es, in part or in w
t to the co
the container for removed parts - V.A.G 1698- .
♦ Some components cannot be removed, or removed only with
difficulty, with the engine installed. Therefore, you should de‐
rrectness of i
termine all defective components before removing engine and
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renew them while engine is removed.

nform
ercia
WARNING
m
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com
tion in

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s
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tions:
do
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sitions. py by
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hot components.
– Read fault memories of all control units before removal ⇒ Di‐

agnosis tester VAS 5051; Guided fault finding; Vehicle system
test or VAS 5052; Vehicle self-diagnosis .
One-piece engine cover
For one-piece engine cover, pull engine cover abruptly upwards
at front and right -arrows A-, then pull forwards out of rear fas‐
tening -arrow B-.


wards at -arrows-.
AG. Volkswagen AG d
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of mounting.
ility
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– Remove air filter housing together with air mass meter and
wit
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connecting pipe.
hole
spec
es, in part or in w
t to the co
– Remove wiper arms ⇒ Electrical system; Rep. gr. 92 ; Wind‐
screen wiper system; Removing and installing wiper arms .
rrectness of i
– Remove plenum chamber cover ⇒ General body repairs, ex‐
terior; Rep. gr. 50 ; Bulkhead; Assembly overview - Bulkhead .
l purpos
Vehicles without anti-theft alarm system
nform
ercia
– Release and disconnect connector from engine control unit

⇒ page 263 , Removing and installing engine control unit.
m
at
om
io
Vehicles with anti-theft alarm system
n
c
in t
or
his
e
– Release connector and pull from engine control unit

at
do
riv
⇒ page 253 , Removing and installing engine control unit with

p
cum
or
theft protection.
f
en
ng
t.
yi Co
Continuation for all vehicles Cop py
t. rig
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pyri by
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– Remove feed-through for engine control unit wiring harness
c by lksw
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4-cylinder diesel engine (1.9
wage
n AlGengine)
. Volkswag-eEdition
n AG d 12.2013
oe
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– Open all cable guide risefasteners -arrows-.
d
nte
ho eo
ut
– Remove wiringss harness from cable guide on longitudinal mem‐ r ac
a
ce
le
un
pt
an
d
itte
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ab
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– Pull off fuel supply hose -2-, fuel return hose -1- and coolant
hose -3-.
ss o
cial p
f i
WARNING
nform
mer
atio
om
n
c
i
or
n thi
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sd
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♦ Wear eye and hand protection when performing any type C py
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– Remove wire from central electrics -arrow-.

– Unscrew earth cable from longitudinal member.

Volkswa
– Pull off or disconnect ageall
n Aother
G. electrical
gen AG
dconnections
oes from en‐
ksw
gine and gearbox
by
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– Separate ho all connecting, vacuum and intake hoses from
ri tee
or en‐
ut
gine.
ss a ac
ce
le
– Remove selector mechanism from gearbox ⇒ 5-speed man‐

un
pt
an
ual gearbox 0A4; Rep. gr. 34 ; Repairing selector mechanism .
d
itte
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erm
ab
– Remove hydraulic clutch slave cylinder ⇒ 5-speed manual
ility
ot p
gearbox 0A4; Rep. gr. 30 .
wit
is n
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spec
t to the co
sition .
rrectne
– Pull connector off oil level and oil temperature sender - G266- .
s
– Pull retainer for oil level and oil temperature sender - G266-
s o
connector off subframe.
cial p
f inform
mer
atio
m
– Completely remove exhaust pipes from auxiliary heater ⇒

o
n
c
Heating, air conditioning; Rep. gr. 82 .

i
or
n thi
te
sd
a
– Pull off coolant hoses on coolant pipes to supplementary heat‐

iv
o
pr
er.
um
r
fo
en
ng
t.
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– Separate all other coolant hoses from engine.
Co
Cop py
ht. rig
– Unbolt left and right drive shafts from gearbox ⇒ Running
rig ht
py by
Vo
gear, axles, steering; Rep. gr. 40 ; Removing and installing
co lksw
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cted agen
drive shafts . Prote AG.

frigerant circuit:
– Remove air conditioner compressor from ancillary bracket ⇒
Heating, air conditioning; Rep. gr. 87 ; Removing and instal‐
ling compressor bracket .
– Secure air conditioner compressor to lock carrier so that re‐
frigerant lines/hoses are free of stress.
Note

– On vehicles with particulate filter remove subframe ⇒ Running

gear, axles, steering; Rep. gr. 40
– Unscrew rear coolant pipe ⇒ page 137 .

– Tighten engine bracket - T10012- on cylinder block with se‐

curing nut and M10 × 25/ 8.8 bolt to approx. 40 Nm.
V.A.G 1383 A- .
jack - V.A.G 1383 A- .

-arrows-.
Note
wage
To remove securing bolts, use stepladder - VAS 5085- . y Vo lks es n
ot g
d b ua
ran
ir se tee
tho
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a ac
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bracket -arrows-.
h re
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spec
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Note
rrectness of i
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Note
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1.4 Securing engine to assembly stand

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When working on the engine, secure it to support clamp - VW 540- t. C rig
gh ht
of the assembly stand using engine and gearbox support - VW pyri by
Vo
co
313- .
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Prote AG.
Procedure
– Disconnect gearbox.

– Attach lifting tackle - 2024 A- as shown and raise engine out

of engine and gearbox jack - V.A.G 1202 A- using workshop
hoist - V.A.G 1383 A- .
Belt pulley end: 2nd hole in hook rail at position 1
Flywheel end: 4th hole in hook rail at position 8
WARNING
The hooks and locating pins must be secured with locking pins.
Note
♦ The holes marked with 1 … 4 of the support bar point to the

belt pulley. agen
AG. Volkswagen AG d
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♦ The holes ed byin
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the hook rails are counted up gfrom
ua the hook.
ran
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– Secure
ss
a engine on support clamp - VW 540- using engine ac and
gearbox jack - VW 313- .
ce
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1.5 Notes on installing

erm
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Installation is carried out in the reverse order. When installing,

wit
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note the following:

hole
spec
– Check clutch release bearing for wear and renew if necessary.

es, in part or in w
t to the co
– Lubricate splines of input shaft lightly with G 000 100.

– Check whether dowel sleeves for centring engine and gearbox
rrectness of i
are in cylinder block and install if necessary.

l purpos
When installing engine, ensure correct position of assembly

mounting:
nf
ercia
– On belt pulley side, ensure that there is a distance -a- of at

or
least 10 mm between engine support and right longitudinal

m
m
atio
member.
om
n in
or c
– The side surface of the engine support -2- should be located

thi
te
sd
parallel to the support arm -1-. Dimension -x- must be identical

iva
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at top and bottom.

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Prote AG.
suitable size, or similar.

AG. Volkswagen AG d
4-cylinder diesel engine (1.9 l engine) - Edition 12.2013 lksw
agen oes
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– Ensure that the edges of the support arm on the gearbox as‐ ho
ris tee
sembly mounting -2- and gearbox support -1- are parallel awith
ut or
ac
one another. Dimension -x- must be identical at top andssbot‐
ce
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nl
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Note
ot p
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♦ Specified torques for assembly mountings ⇒ page 27
hole
spec
♦ Electrical connections and routing ⇒ Electrical system; Rep.
es, in part or in w
t to the co
gr. 97
Procedure
rrectness of i
– Install pendulum support.
– Install drive shafts ⇒ Running gear, axles, steering; Rep. gr. l purpos
40 ; Removing and installing drive shafts .
nform
ercia
– Install front exhaust pipe ⇒ page 267 .

m
at
om
io
Vehicles with manual gearbox
n
c
in t
or
his
e
– Install slave cylinder for hydraulic clutch ⇒ 6-speed manual

at
do
riv

p
cum
or

f
en
ng
t.
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– Remove selector mechanism from gearbox ⇒ 6-speed man‐ Cop py
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ual gearbox 02S; Rep. gr. 34 ; Repairing selector mechanism . opyri
gh by
Vo
ht
by c lksw
Vehicles with four-wheel drive: Prote
cted AG.
agen
– Install selector mechanism on gearbox ⇒ 6-speed manual

gearbox 02Q, four-wheel drive; Rep. gr. 34 ; Repairing selec‐
tor mechanism .
– Install pressure line for hydraulic clutch mechanism.
– Install front propshaft ⇒ Final drive 02D, 0AV; Rep. gr. 39 ;
– On vehicles with particulate filter install subframe ⇒ Running
gear, axles, steering; Rep. gr. 40
– Install alternator ⇒ Electrical system; Rep. gr. 27 ; Removing
and installing alternator and poly V- belt .
– Install air conditioner compressor ⇒ Heating, air conditioning;
Rep. gr. 87 ; Removing and installing compressor bracket.
– Install poly V-belt ⇒ page 31 .
– Install noise insulation ⇒ General body repairs, exterior; Rep.
gr. 50 ; Assembly overview - Body - front .
– Install engine control unit ⇒ page 251 .
– Install plenum chamber bulkhead ⇒ General body repairs,
head .
– Fill coolant system with coolant ⇒ page 125 .
– Carry out road test and then read fault memory ⇒ page 251 .

Specified torques
Threaded connection Specified torque
Bolts, nuts M6 10 Nm
M8 20 Nm
M10 45 Nm
M12 60 Nm
1.6 Assembly mountings

Engine assembly mountings
A = 20 Nm + 90° further 1)
B = 40 Nm + 90° further 1)
C = 60 Nm + 90° further 1)
1) Renew.
Gearbox assembly mounting

A = 40 Nm + 90° further 1)
B = 60 Nm + 90° further 1)
1) Renew. AG. Volkswagen AG d
agen oes
olksw not
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or eo
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pt
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ot p
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es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
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ate
do
priv
cum
for
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Cop py
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Prote AG.

AG. Volkswagen AG d
agen o
Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat Vol2006 ➤ , Touran 2003 ➤
ksw es n
ot g
by ua
4-cylinder diesel engine (1.9 l engine)
rised - Edition 12.2013 ran
t ee
tho or
au ac
Pendulum support ss
ce
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un
Always note the size and property class of the bolt. Different
pt
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d
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specified torques are valid.
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wit
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spec
From model year 08, in manual gearboxes 02Q Heli Coil in‐
serts are installed in the threaded connections to pendulum
t to the co
support. Differentiation ⇒ Rep. gr. 34
For these and all other gearboxes class 10.9 bolts must be
rrectne
used.
If Heli Coil inserts are not fitted in manual gearboxes 02Q, use
s
class 8.8 bolts and the specified torques.
s o
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Bolt -A-
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M10 x 35 property class 8.8: turn 40 Nm + 90° further
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Bolt -C-
M14 x 1.5 x 70
100 Nm + 90° turn
Do not tighten until pendulum support is bolted on gearbox

13 – Crankshaft group
1 Dismantling and assembling engine
⇒ “1.1 Assembly overview - poly V-belt drive”, page 29
⇒ “1.2 Assembly overview - toothed belt drive”, page 32
⇒ “1.3 Removing and installing engine support”, page 34
⇒ “1.4 Assembly overview - crankcase”, page 36
Note
If large quantities of swarf or metal particles (caused, for example,

by partial seizure of the crankshaft or conrod bearings) are found
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1.1 Assembly overview - poly V-belt drive
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⇒ “1.1.1 Removing poly V-belt”, page 30

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2 - 25 Nm rrectness of i
3 - Alternator
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4 - Bracket
❑ For alternator and air
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conditioner compressor.
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5 - Poly V-belt tensioning ele‐

ion in
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7 - Air conditioner compressor
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8 - 25 Nm
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9 - Dowel sleeves
10 - Poly V-belt
❑ Mark direction of rota‐
tion before removing
❑ Check for wear
❑ Do not kink
❑ Removing and installing
⇒ page 30
1. Dismantling and assembling engine 29

1.1.1 Removing poly V-belt

Special tools and workshop equipment required
♦ Locking pin - T10060 A-
♦ 16 mm open-end spanner - T 10241-
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– Remove noise insulation. ⇒ General body repairs, exterior;

es, in part or in w
Rep. gr. 50 ; Body - front; Assembly overview .

t to the co
– Remove lower part of front right wheel housing liner ⇒ General

body repairs, exterior; Rep. gr. 66 ; Removing and installing
rrectness of i
wheel housing liner .

l purpos
WARNING
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– Golf, Golf Plus, Touran: Pull fuel filter out of bracket and place Prote AG.
it with hoses to one side.
30 Rep. gr.13 - Crankshaft group

– Only Passat: Separate plug-in connectors of fuel lines

-arrows-.
Note
Do this by lifting catch of plug-in connectors.
All other vehicles continued

– Unbolt fuel filter from engine assembly mounting and lay to
side (hoses remain connected).
– Mark direction of rotation of poly V-belt.
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– Swing tensioning element in direction of arrow to remove
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– Lock tensioning element using locking pin - T10060 A- .

– Remove poly V-belt.
nform
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1.1.2 Installing poly V-belt

– Install in reverse order.
Note
♦ Before installing poly V-belt, ensure that all ancillaries (alter‐

nator, air conditioner compressor) are secured tightly.
♦ When installing poly V-belt, check direction of belt rotation and
proper seating of belt in pulleys.
♦ Lastly, place poly V-belt over alternator.
– Only Passat: Install fuel filter. Specified torque: 10 Nm

After completing repairs always:

– Start engine and check belt running.

Belt drive without air conditioner compressor
Belt drive with air conditioner compressor
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1.2 Assembly overview - toothed belt drive
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1 - Toothed belt guard upper

part
2 - 100 Nm
3 - 25 Nm
4 - Camshaft pulley
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6 - 10 Nm
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7 - Stud
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8 - Rear toothed belt guard
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10 - Sealing grommet
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11 - 20 Nm + turn (45°)
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install ⇒ page 34 .
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14 - Idler roller
15 - Coolant pump
❑ Removing and installing ⇒ page 129
16 - Crankshaft pulley
17 - 120 Nm + turn 90° further
❑ Renew
❑ Use counterhold - 3415- to loosen and tighten.
❑ Do not additionally oil or grease thread and shoulder.
❑ Turning further can be done in several stages.
18 - 15 Nm
19 - Toothed belt guard lower part
20 - Belt pulley and vibration damper
❑ Can only be installed in one position, holes are offset.
21 - 10 Nm + turn (90°)
❑ Renew
22 - Cover
23 - Toothed belt
❑ Mark direction of rotation before removing

❑ Check for wear
❑ Do not kink
❑ Removing, installing and tensioning ⇒ page 70
24 - 40 Nm + turn (180°)
❑ Renew
25 - Toothed belt guard centre part
26 - Engine bracket
1.3 Removing andninstalling engine support

AG. Volkswagen A
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♦ Support bracket
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ss - V.A.G 1331-
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– Remove engine cover.
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– To do this, pull engine cover upwards abruptly at front and right
ility
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-arrows A- and then pull forwards out of rear fastening
wit
-arrow B-.
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– Separate plug-in connectors of fuel lines -arrows-.
Note
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– Lay fuel filter with hoses to side.
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– Disconnect coolant hose from top of expansion tank.
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– Remove expansion tank and lay it to side.
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– Remove charge air pipe between charge air cooler and turbo‐
h re
ole,
charger.
spec
– Carefully cover or seal open ends.
t to the co
Golf, Golf Plus and Touran:
rrectne
– Fit engine support bracket - 10-222A- with adapters - 10-222A/
13- and take up weight of engine in installation position.
ss o
cial p
f inform
mer
atio
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– Remove securing bolts from assembly mounting/engine sup‐ cted agen
Prote AG.
port -arrows- and remove complete assembly mounting.
Note
♦ The assembly mounting may only be removed if the engine is

supported with support bracket 10-222A!
♦ The engine support must only be loosened when the assembly
mounting has been removed.
WARNING
When raising and lowering engine using support bracket -

10-222A- , ensure that no components or hoses are damaged,
strained or torn off.

Rep. gr. 50 ; Body - front; Assembly overview - noise insula‐
tion .
– Remove front right wheel housing liner.

– Raise engine with support bracket - 10-222A- until both upper

bolts of engine support can be loosened and removed.
– Lower engine with support bracket - 10-222A- until lower bolt
can be loosened and removed.
– Remove engine support upwards.
Installing
– Position engine support from above on cylinder block.
– Start new bolts and tighten hand-tight.
AG. Volkswagen AG d
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The tightening sequence
o
auth and specified torques for the engine eo
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support securing
ss bolts must always be followed. Otherwise the c
engine support can be stressed and it can break.
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– Tighten bolts for engine support in the sequence shown
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-1…3- to 40 Nm + (180°) turn further. To do this, raise or lower
h re
engine using support bracket - 10 - 222 A- .
hole
spec
es, in part or in w
I : Engine support with less clearance to engine
t to the co
II: Engine support with greater clearance to engine
Note rrectness of i
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Before installing assembly mounting, tighten all engine support

nf
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bolts to prescribed torque.

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– Install assembly mounting between engine and body, renew

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securing bolts ⇒ page 27 .

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– Bolt engine assembly mounting to engine support -arrows- by
by lksw
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bringing contact surfaces together using support bracket -
AG.
10-222A- . Specified torque: 60 Nm + turn 90° further.

Further assembly is basically the reverse of the dismantling se‐
quence. In the process, note the following:
♦ Ensure that fuel hose connections are tight.
♦ Do not interchange supply line and return line (return line blue
or with blue marking, supply line black).
♦ When installing charge air pipes, ensure that locking lugs en‐
gage correctly.
– Install wheel housing liner.
– Install noise insulation. ⇒ General body repairs, exterior; Rep.
gr. 50 ; Body - front; Assembly overview - noise insulation .
1.4 Assembly overview - crankcase

1 - Cylinder block
sealing flange and fly‐
wheel ⇒ page 38 .
crankshaft
⇒ page 52 .
❑ Dismantling and assem‐
bling pistons and con‐
rods ⇒ page 52
2 - Seal
❑ Renew
3 - Oil filter bracket
bling ⇒ page 115
4 - 15 Nm + turn (90°)
AG. Volkswagen AG d
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lower right bolts and ut ho eo
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then tighten all 4 boltsss in
a c
diagonal sequence.
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5 - Bracket
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6 - 20 Nm
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❑ For thermostat
spec
es, in part or in w
8 - 15 Nm
t to the co
9 - O-ring
❑ Renew
10 - Thermostat rrectness of i
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⇒ page 129
nf
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❑ Observe installation position ⇒ page 129 , removing and installing thermostat.

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❑ Checking: heat thermostat in water.

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❑ Begins to open at approx. 85°C

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❑ Ends at approx. 105 °C

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❑ Opening lift at least 7 mm.

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11 - Hexagon bolt t. Cop py
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❑ Tightening sequence and torque specifications ⇒ Heating, air conditioning; Rep. gr. 87 ; Removing and
ht
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installing compressor bracket .
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12 - Bracket
❑ For alternator, if air conditioner compressor is fitted
13 - Poly V-belt tensioning element
14 - 25 Nm
15 - Oil sump
❑ Clean sealing surface before fitting.
❑ Install with sealant according to ⇒ Electronic Parts Catalogue (ETKA)
16 - 15 Nm

2 Removing and installing sealing

flange and flywheel
⇒ “2.1 Assembly overview - sealing flanges and flywheel”,
page 38
⇒ “2.3 Renewing crankshaft oil seal - pulley end”, page 40
⇒ “2.3 Renewing crankshaft oil seal - pulley end”, page 40
⇒ “2.2 Removing and installing dual-mass flywheel”, page 39
⇒ “2.5 Renewing crankshaftwsealing
gen AG flange - flywheel
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2.1 Assembly overview - sealing flanges and
au
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Repairing clutch ⇒ 6-speed manual gearbox 02S; Rep. gr. 30 ; Repairing clutch .
ility
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spec
1 - Seal
t to the co
❑ Do not additionally oil or
grease the oil seal seal‐
ing lip.
rrectne
❑ Before installing, re‐
move residue from
s
crankshaft journal using

s o
a clean cloth.
cial p
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❑ Renewing crankshaft oil

mer
seal - belt pulley end

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⇒ page 40 .
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❑ Must sit on dowel

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❑ Insert with sealant as
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Prote AG.
Catalogue (ETKA)
⇒ page 42
3 - Cylinder block
crankshaft
⇒ page 52 .
bling pistons and con‐
rods ⇒ page 52
4 - 60 Nm + turn (90°)
❑ Renew
5 - Flywheel
❑ To remove and install
flywheel, counterhold
with 3067
dual-mass flywheel ⇒ page 39

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❑ Must sit on dowel sleeves
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❑ Do not damage or bend when assembling
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7 - 15 Nm
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❑ Renew
spec
es, in part or in w
8 - Sealing flange with oil seal
t to the co
❑ Renew complete with oil seal and sender wheel only.
rrectness of i
9 - Removing and installing engine speed sender - G28- ⇒ page 284 .
l purpos
❑ Loosen and tighten using commercially available ball-ended hexagon key socket
❑ Specified torque: 5 Nm
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2.2 Removing and installing dual-mass fly‐

or
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♦ Counterhold - 3067-
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Removing
– Remove gearbox ⇒ Power transmission; Rep. gr. 37 ; Re‐
moving and installing gearbox .
Caution
To prevent damage to the dual-mass flywheel when removing,

the bolts -B- must not be removed with an impact wrench or
similar. The bolts may be removed only by hand.
– Mark position of dual-mass flywheel in relation to engine.

– Rotate the dual-mass flywheel -A- so that the bolts -B- align
centrally with the holes -arrows-.
– When unscrewing bolts -B-, ensure that none of the bolt heads
come into contact with the dual-mass flywheel -arrows-. The
flywheel will otherwise be damaged when the bolts are un‐
screwed further.
2. Removing and installing sealing flange and flywheel 39

– Insert counterhold - 3067- in hole on cylinder block -B-.

– Unscrew dual-mass flywheel.
Installing
note the following:
• Specified torque ⇒ Item 4 (page 38)
– Use new bolts for securing.
– Insert counterhold - 3067- in hole on cylinder block -A-.
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2.3 Renewing crankshaft oil seal - pulley end

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equipment required
♦ Oil seal extractor - 3203-
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♦ Assembly tool - T10053+3- Volksw
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♦ Torque wrench - orise nte
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V.A.G 1331- auth
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♦ Torque wrench -
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pt
V.A.G 1332-
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ate
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Cop py
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2.3.1 Removing
– Remove toothed belt. ⇒ page 70
– Remove crankshaft toothed belt pulley. To do this, lock tooth‐
ed belt pulley using counterhold - 3099- .
Note
When bolting on counterhold, place two washers between tooth‐

ed belt pulley and counterhold.
– To guide oil seal extractor - 3203- , screw central bolt by hand

into crankshaft to stop.
– Unscrew inner part of oil seal extractor two turns (approx. 3
mm) out of outer part and lock with knurled screw.
– Oil threaded head of oil seal extractor.

– Using great pressure, screw oil seal extractor as far as possi‐

ble into seal.
– Loosen knurled screw and turn inner part against crankshaft
until oil seal is pulled out.
2.3.2 Installing
Note
The oil seal sealing lip must not be additionally oiled or greased.
– Remove oil residue from crankshaft journal using clean cloth.

– Place guide sleeve - T10053/1- onto crankshaft journal.
– Slide oil seal over guide sleeve onto crankshaft journal.
AG. Volkswagen AG d
– Press oil seal in to stop using assembly tool - T10053- and ksw
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– Install and tighten toothed belt ⇒ page 70 . utho eo
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2.4 Removing and installing sealing flange - pulley end

rrectness o
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mer
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Rep. gr.13 - Crankshaft group Prote AG.

equipment required
♦ Assembly tool - T10053-
♦ Torque wrench -
V.A.G 1331-
♦ Torque wrench -
V.A.G 1332-
♦ Hand drill with plastic brush
attachment
♦ Sealant as per ⇒ Electronic
Parts Catalogue (ETKA)
♦ Flat scraper
AG. Volkswagen AG d
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2.4.1 Removing
du
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– Remove crankshaft toothed belt pulley. To do this, lock tooth‐

, is n
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ed belt pulley using counterhold - 3099- .

hole
spec
es, in part or in w
t to the co
Note
When bolting on counterhold, place two washers between tooth‐

rrectness of i
ed belt pulley and counterhold.

l purpos
– Drain engine oil.

nform
ercia
– Remove sump ⇒ page 111 .

m
at
– Pull off front sealing flange.

om
ion
c
in t
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– Remove sealing flange; if necessary, loosen by applying light

o
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blows with a rubber-headed hammer.

a
do
priv
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or
– Remove sealant residue from cylinder block with a flat scraper.

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cted agen
Prote AG.

– Remove residual sealant from sealing flange using a plastic

rotary brush (wear eye protection).
– Clean sealing surfaces. They must be free of oil and grease.
AG. Volkswagen AG d
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2.4.2 Installing
, is n
h re
hole
spec
es, in part or in w
t to the co
Note
♦ Observe expiry date of sealing compound.
rrectness of i
♦ The sealing flange must be installed within 5 minutes of ap‐
l purpos
plying the silicone sealant.
nform
– Cut off tube nozzle at forward marking (∅ of nozzle approx. 3
ercia
mm).
m
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tion in
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te o
Note
thi
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c
♦ The sealant bead must not be thicker than 2… 3 mm, other‐
um
fo
en
g
wise excess sealant can enter sump and block the strainer in
n
t.
yi Co
oil pump suction pipe, as well as drip onto the sealing surface Cop py
t. rig
of crankshaft oil seal. gh ht
pyri by
Vo
co lksw
♦ Before applying sealant bead, cover sealing surface of oil seal
by
cted agen
Prote
with a clean cloth.
AG.
– Apply silicone sealant bead as shown to the clean sealing sur‐

face of sealing flange.
– Install sealing flange immediately and tighten all bolts lightly.
Note
When fitting sealing flange with oil seal installed use guide sleeve
- T10053/1- .
– Tighten securing bolts for sealing flange to 15 Nm using alter‐

nate and diagonal sequence.
– Install sump ⇒ page 111 .
Note
Sealing compound must dry for approx. 30 minutes after instal‐

lation. Only then fill with engine oil.
Installing toothed belt and adjusting valve timing. ⇒ page 70

2.5 Renewing crankshaft sealing flange -

flywheel end
♦ Assembly tool - T10134-
♦ Torque wrench - V.A.G 1331-

♦ Socket - V.A.G 1332/11-
♦ Vernier gauge
♦ Three hexagon bolts M 6 x 35 mm
♦ Two hexagon bolts M 7 x 35 mm
2.5.1 Pressing out sealing flange with sender

wheel
lkswage es n
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Note d byV ua
ran
ir se tee
tho
or
♦ For the sake of clarity, the work is performed with
ss
the
au
engine ac
removed.
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le
un
pt
an
♦ The procedure is identical whether the engine is installed or
d
itte
y li
removed.
erm
ab
ility
ot p
wit
is n
– Remove flywheel.
h re
ole,
– Remove intermediate plate.
spec
t to the co
– Set engine to TDC No. 1 cylinder ⇒ page 70 , Removing and
installing toothed belt.
– Remove sump ⇒ page 111 . rrectne
– Remove engine speed sender - G28- -arrow- using a com‐

mercially available ball-ended hex key socket ⇒ page 284 .
ss o
cial p
– Unscrew sealing flange securing bolts.

inform
mer
atio
m
Note
o
n
c
i
or
n thi
te
sd
Sealing flange and sender wheel are pressed off the crankshaft
iva
o
r
together using three M 6 x 35 mm bolts.

p
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fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

– Screw three M 6 x 35 mm bolts into threaded holes -arrows-

of sealing flange.
– Screw bolts alternately (max. 1/2 turn 180° for each bolt) into
sealing flange and press sealing flange together with sender
wheel off crankshaft.
2.5.2 Pressing in sealing flange with sender

wheel
Note
♦ The sealing flange with a PTFE seal is equipped with a sealing

lip support ring. This support ring serves as a fitting sleeve and
must not be removed prior to installation.
♦ Sealing flange and sender wheel must not be separated or
turned after removal from packaging.
♦ The sender wheel is held in its installation position on the as‐
sembly device - T10134- by a locating pin.
olkswagen AG
en AG. V
♦ Sealing flange and oil seal form one
olks unit and must only be s not
wag doe
renewed together with the sender
ed
by wheel.
V gu
ara
ris nte
♦ The assembly device - T10134-
utho is held in its position relative eo
ra
sa
to the crankshaft by a sguide pin inserted into a hole in the c
crankshaft.
ce
le
un
pt
an
d
itte
y li
Assembly tool - T10134-

erm
ab
ility
ot p
A - Clamping surface
wit
is n
h re
B - Hexagon nut
ole,
spec
C - Assembly housing
t to the co
D - Locating pin
E - Hexagon socket head bolt
rrectne
F - Guide pin for diesel engines (black knob)

ss
G - Guide pin for petrol engines (red knob)

o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

2.5.3 A - Assembling seal with sender wheel

on assembly tool - T10134-
– Screw in hexagon nut -B- to just before clamping surface -A-
of threaded spindle.
– Clamp assembly device - T10134- in a vice on clamping sur‐

face -A- of threaded spindle.
AG. Volkswagen AG d
agen oes
– Press assembly housing -C- downwards until it lies on hexa‐
Vol
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gu
gon nut -B- -arrow-. se
d by ara
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Note
ce
e
nl
pt
du
an
itte
Inner part of assembly tool and assembly housing must be at
y li
erm
ab
same height.
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
– Remove securing clip -arrow- from new sealing flange.
t to the co
Note
rrectness of i
l purpos
The sender wheel must not be taken out of the sealing flange or
twisted.
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
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f
– Locating hole -A- on sender wheel -C- must align with marking
en
ng
t.
yi Co
-B- on sealing flange. t. Cop py
rig
gh ht
– Place sealing flange with front side downwards on a clean flat yri
p by
o Vo
surface.
c by lksw
cted agen
Prote AG.

AG. Volkswagen AG d
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olksw not
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Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006a➤ut , Touran 2003 ➤ ra
c
s
4-cylinder diesel engine (1.9 l engine) - Edition 12.2013 s
ce
e
nl
pt
du
an
itte
– Push sealing lip support ring -A- downwards in direction of ar‐
y li
erm
ab
row until it lies on flat surface.
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
– Upper edge of sender wheel and front edge of sealing flange mercia
at
must align -arrows-. om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
– Place sealing flange with front side on assembly tool - T10134-

so that locating pin -B- can be inserted in sender wheel hole
-A-.
Note
Ensure sealing flange lies flat on assembly tool.
– Push sealing flange and support ring for sealing lip -B- against
surface of assembly tool - T10134- whilst tightening the three
knurled screws -A- so that locating pin cannot slide out of
sender wheel hole.
Note
When installing sealing flange, ensure that sender wheel remains

fixed in assembly device.
2.5.4 B - Attaching assembling tool - T10134-

with sealing flange on crankshaft flange
• Crankshaft flange must be free of oil and grease.
• Engine positioned at TDC No. 1 cylinder.

. Volkswage
Golf 2004 k➤ wa, gGolf
en AGPlus 2005n➤AG,do
Passat
es n 2006 ➤ , Touran 2003 ➤
ol s ot g
d by V 4-cylinder diesel engine (1.9 luengine)
a r
- Edition 12.2013
e an
ris tee
ho
– Screw hexagon nut -B- to end auof threaded
t
spindle. or
ac
ss
– Press threaded spindle of assembly tool - T10134- in direction
ce
e
nl
pt
du
of arrow, until hexagon nut -B- lies against assembly housing
an
itte
y li
-A-.
erm
ab
ility
ot p
– Align flat side of assembly housing on sump side of crankcase
wit
, is n
sealing surface.
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
– Secure assembly tool - T10134- to crankshaft flange using

hexagon socket head bolts -A-.
nf
ercia
orm
m
Note
atio
om
n in
or c
Screw hexagon socket head bolts -A- into crankshaft flange (ap‐
thi
te
sd
a
prox. 5 full turns).

iv
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
– To guide sealing flange, screw two M 7 × 35 mm bolts -A- into
cylinder block.
2.5.5 C - Bolting assembly tool - T10134- onto

crankshaft flange
– Push assembly housing -C- by hand in direction of arrow until
sealing lip support ring -B- contacts crankshaft flange -A-.
– Push guide pin for diesel engines (black knob) -D- into hole in
crankshaft. This ensures that the sender wheel reaches its fi‐
nal installation position.
Note
The guide pin for petrol engines (red knob) -F- must not be inser‐
ted in threaded hole of crankshaft.
– Hand-tighten both hexagon socket head bolts of assembly

tool.
– Screw hexagon nut -E- onto threaded spindle by hand until it
lies on assembly housing -C-.

2.5.6 D - Pressing sender wheel onto crank‐

shaft flange using assembly tool -
T10134-
– Tighten hexagon nut of assembly tool - T10134- to 35 Nm us‐
ing torque wrench - V.A.G 1331- and tool insert, 24 mm - V.A.G
1332/11- .
Note
After hexagon nut is tightened to 35 Nm, a small air gap must still
be present between cylinder block and sealing flange.
2.5.7 E - Checking sender wheel installation

position on crankshaft
– Screw hexagon nut -E- to end of threaded spindle.
– Remove the two bolts -A- from cylinder block.
– Screw the three knurled screws -B- out of sealing flange.
– Remove assembly tool - T10134- .
– Remove sealing lip support ring.
lkswage es n
o ot g
yV
– The sender wheel is in ithe sed correct installation position on the ran
b ua
crankshaft if a gap -a- h = 0.5 mm exists between crankshaft
or tee
ut or
flange -A- and sender
ss
a wheel -B-. ac
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
– Set vernier gauge on crankshaft flange.

l purpos
– Measure distance -a- between crankshaft flange and sender

wheel.
nf
ercia
If distance -a- is too small:

orm
m
atio
– Press sender wheel further. ⇒ page 51

om
n in
c
If distance -a- is attained:

or
thi
te
sd
iva
– Tighten new securing bolts for sealing flange to 15 Nm using

o
r
rp
cu
alternate and diagonal sequence.

o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

– Install engine speed sender - G28- -arrow- and tighten secur‐

ing bolt to 5 Nm.
– Install sump ⇒ page 111 .
– Install intermediate plate.
– Install flywheel using new bolts. Tighten securing bolts to
60 Nm + turn 90° further.
2.5.8 F - Re-pressing sender wheel

– Secure assembly tool - T10134- to crankshaft flange using
hexagon socket head bolts -A-.
– Hand tighten both hexagon socket head bolts.
– Push assembly tool - T10134- by hand to sealing flange.
– Screw hexagon nut -E- onto threaded spindle by hand until it

lies on assembly housing -C-.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
– Tighten hexagon nut of assembly tool - T10134- to 40 Nm us‐

h re
hole
ing torque wrench - V.A.G 1331- and tool insert, 24 mm - V.A.G

spec
1332/11- .
es, in part or in w
t to the co
– Check installation position of sender wheel on crankshaft

again. ⇒ page 50
rrectness of i
If dimension -a- is still too small:

l purpos
– Tighten hexagon nut for assembly tool - T10134- to 45 Nm.

– Check installation position of sender wheel on crankshaft
nform
ercia
again. ⇒ page 50
m
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
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t.
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Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

3 Crankshaft
⇒ “3.1 Assembly overview - crankshaft”, page 52
3.1 Assembly overview - crankshaft

⇒ “3.1.1 Crankshaft dimensions”, page 52
⇒ “3.1.2 Renewing needle bearing in crankshaft - vehicles with
dual clutch gearbox ”, page 53
1 - Bearing shells 1, 2, 4 and 5

❑ For bearing cap without
oil groove.
❑ For cylinder block with
oil groove.
❑ Do not interchange
used bearing shells
(mark).
2 - 65 Nm + turn (90°)
❑ Renew
❑ To measure radial clear‐
ance, tighten to 65 Nm
but not further.
3 - Bearing cap
❑ Bearing cap 1: belt pul‐
ley end n AG. Volkswagen AG do
swage es n
❑ Bearing cap 3 with re‐ yV
olk ot g
ua
cesses for thrust wash‐ ir se
d b ran
tee
ers. utho
or
a ac
❑ Bearing shell retaining ss
ce
e
lugs in cylinder block

nl
pt
du
and bearing caps must an

itte
y li
align.
erm
ab
ility
ot p
4 - Bearing shell 3
wit
, is n
❑ For bearing cap without

h re
hole
oil groove.
spec
es, in part or in w
❑ For cylinder block with

t to the co
oil groove.
5 - Thrust washer
rrectness of i
❑ For bearing cap 3.

l purpos
❑ Note fixing arrange‐

ment.
nform
ercia
6 - Crankshaft
m
❑ Axial clearance new: 0.07 … 0.17 mm wear limit: 0.37 mm

at
om
io
❑ Check radial clearance with Plastigage new: 0.03…0.08 mm, wear limit: 0.17 mm
n
c
in t
or
his
e
❑ Do not rotate crankshaft when checking radial clearance.

at
do
riv
❑ Crankshaft dimensions ⇒ page 52 .

p
cum
for
en
g
7 - Thrust washer
n
t.
yi Co
op py
❑ For cylinder block, bearing 3
t. C rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
3.1.1 Crankshaft dimensions

(Dimensions in mm)

Honing dimen‐ Crankshaft bearing Conrod

sion journal diameter journal diameter
Basic dimension 54.00 -0.022 47.80 -0.022
-0.042 -0.042
3.1.2 Renewing needle bearing in crankshaft

- vehicles with dual clutch gearbox
6-speed dual clutch gearbox: If the engine or gearbox has to be
removed during repairs, check needle bearing in crankshaft. If it
is damaged or tarnished blue, it must be renewed.
– If it is not damaged, lightly grease with high-temperature
grease - G052133A2- .
7-speed dual clutch gearbox: Always renew needle bearing when

removing engine or gearbox.
6-speed dual clutch gearbox
olkswagen AG
en AG. V
- This gearbox canolkbe
swaidentified by the gearbox
g does
notoil cooler.
V gu
by a
Special tools,
or
ise testers, measuring instruments and auxiliary
d ran
tee items
requiredauth or
a
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
53
cted agen
Prote AG.
3. Crankshaft
1 - -1- Kukko 21/2

2 - Centring mandrel - 3176-
3 - Drift - VW 207 C-
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
Puller - T10055- with adapter -T10055/3-

rm
m
atio
m
Procedure
o
n in
or c
• Gearbox is separated from engine

thi
te
sd
iva
o
r
Pulling needle bearing out:

rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

– Pull out needle roller bearing using Kukko 21/2, adapter -

T10055/3- and puller - T10055- .
7-speed dual clutch gearbox

No gearbox oil cooler is installed.
Always renew needle bearing when removing engine or gearbox.
Special tools, testers, measuring instruments and auxiliary items
required
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
3. Crankshaft 55
1 - -1- Kukko 21/2 and -4- Kuk‐

ko 22/1
2 - Centring mandrel - 3176-
3 - Drift - VW 207 C-
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
Procedure
sd
iva
o
pr
cum
r
• Gearbox is separated from engine

fo
en
ng
t.
yi Co
Pulling needle bearing out: t. Cop py
rig
gh ht
yri
– Pull out using commercially available puller -A-, e.g. Kukko p by
o Vo
by c
21/2 and Kukko 22/1.
lksw
cted agen
Prote AG.
Installing

– Drive needle bearing in with drift - VW 207 C- or with centring

mandrel - 3176- .
– Carefully drive needle bearing in.
– Always measure the driving depth when driving in.
Renew bearing if it has been driven in too far.
• Driving depth: Dimension -a- = 1.5 to 1.8 mm.

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
3. Crankshaft 57
4 Pistons and conrods

⇒ “4.1 Assembly overview - pistons and conrods”, page 58
⇒ “4.2 Separating new conrod”, page 59
⇒ “4.3 Checking piston projection at TDC”, page 60
⇒ “4.4 Piston and cylinder dimensions”, page 61
. Volkswagen AG
a gen AG does
⇒ “4.5 Piston rings, cylinder bore and piston installation position”,
Vol
ksw not
gu
page 61 ed by ara
nte
ris
tho eo
4.1 Assembly overview - pistons
ss
au and conrods ra
c
ce
le
un
pt
an
d
1 - Piston rings
itte
y li
rm
ab
❑ Offset gaps by 120°.
pe
ility
ot
❑ Use piston ring pliers to
wit
, is n
h re
remove and install.
hole
spec
❑ “TOP” faces towards
es, in part or in w
piston crown.
t to the co
❑ Checking ring gap
⇒ page 61 .
rrectness of i
❑ Checking ring-to-groove
clearance ⇒ page 62 .
l purpos
2 - Piston
nform
ercia
❑ With combustion cham‐

ber.
m
a
com
t
❑ Mark installation posi‐
ion in
tion and cylinder num‐
r
te o
thi
ber.
s
iva
do
r
❑ Installation position and

rp
cum
fo
allocation of piston to
en
ng
t.
yi
cylinder ⇒ page 63 .
Co
Cop py
t.
❑ Arrow on piston crown
rig
gh ht
yri by
points to belt pulley end. op Vo
by c lksw
cted agen
❑ Install using piston ring Prote AG.
clamp.
❑ If piston skirt is cracked,
renew piston.
❑ Checking piston projec‐
tion at TDC
⇒ page 60 .
3 - Piston pin
❑ If difficult to remove,
heat piston to 60°C
❑ Remove and install us‐
ing drift - VW 222- .
4 - Circlip
5 - Conrod
❑ Mark cylinder allocation -A- with coloured pen.
❑ Installation position: Marking -B- faces towards pulley end.
❑ With industrially cracked conrod cap.
6 - Bearing shell
❑ Note installation position
❑ Note version: Upper bearing shell (towards piston) is made of a more wear resistant material. Identifi‐
cation: Black line on bearing surface in area of joint.

❑ Do not interchange used bearing shells.
❑ Insert bearing shells centrally.
❑ Ensure secure seating
❑ Axial clearance, wear limit: 0.37 mm
❑ Check radial clearance with Plastigage: Wear limit: 0.08 mm, do not rotate crankshaft when checking
radial clearance
7 - Cylinder block
❑ Checking cylinder bores ⇒ page 62 .
❑ Piston and cylinder dimensions ⇒ page 61 .
8 - Conrod bearing cap
❑ The caps fit only on the corresponding conrod and in only one position due to the cracking procedure for
separating the cap from the conrod.
9 - Oil spray jet
❑ For piston cooling.
Note
When renewing the oil spray jet, en‐

sure correct allocation to the piston
⇒ Electronic Parts Catalogue (EK‐
AG. Volkswagen AG d
TA) . lksw
agen oes
not
Vo gu
by ara
d
10 - 25 Nm horise nte
eo
ut
❑ Insert without sealant ss a ra
c
ce
e
11 - Conrod bolt, 30 Nm + turn (90°)

nl
pt
du
an
itte
❑ Renew
y li
erm
ab
❑ Oil threads and contact surface
ility
ot p
wit
❑ Use old bolt for measuring radial clearance
, is n
h re
hole
spec
es, in part or in w
t to the co
4.2 Separating new conrod
– Mark cylinder allocation of conrod ⇒ Item 5 (page 58)
– Lightly clamp the conrod in a vice using aluminium vice rrectness of i
l purpos
clamps, as shown in the illustration.

nform
ercia
Note
m
at
om
io
♦ To prevent damage to the conrod, only clamp conrod in lightly.

n
c
in t
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♦ Clamp conrod in below the marked line.

at
do
priv
cum
or
– Unscrew the two bolts -arrows- approx. 5 turns.

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4. Pistons and conrods 59

– Using a plastic hammer, carefully knock against conrod bear‐

ing cap -arrow- until it is loose.
4.3 Checking piston projection at TDC

♦ Measuring bridge - VW 382/7-
AG. Volkswagen AG d
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♦ End dimension plate - VW 385/17-
ility
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es, in part or in w
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nf
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m
atio
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♦ Dial gauge
o
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Test procedure
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Note
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If different values are determined during the projection measure‐
rig by
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ment, use the largest dimension for selecting the gasket. by c lksw
cted agen
Prote AG.

Piston projection at TDC must be measured when installing new

pistons or a short engine. Install the appropriate cylinder head
gasket depending upon piston projection, according to following
table:
Note
Turn engine clockwise to measure piston projection at TDC.
Piston projection Identification

Holes/notches
0.91 mm … 1.00 mm 1
1.01 mm … 1.10 mm 2
1.11 mm … 1.20 mm 3
Cylinder head gasket identification

♦ Part No. = arrow 1
♦ Production control code = arrow 2 (can be disregarded)
olks
wage es n
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♦ Holes = arrow 3 db ran
rise tee
tho or
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un
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hole
spec
4.4 Piston and cylinder dimensions
es, in part or in w
t to the co
Honing dimension Piston ∅ Cylinder bore ∅
Basic dimen‐ mm 79.47 79.51
rrectness of i
sion
l purpos
Stage I mm 79.72 79.76

Stage II mm 79.97 80.01
nform
ercia
4.5 Piston rings, cylinder bore and piston in‐

m
a
com
ti
stallation position
on in
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te o
thi
Checking piston ring gap

s
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Cop py
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rig ht
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Prote AG.

♦ Feeler gauges
– Push piston ring squarely from above down to approx. 15 mm
from bottom end of cylinder.
Piston ring New Wear limit
dimensions in mm
1st compression ring 0.20 ... 0.40 1.0
2nd compression ring 0.20 ... 0.40 1.0


dimensions in mm
Oil scraper ring 0.25 ... 0.50 1.0
Checking ring-to-groove clearance

♦ Feeler gauges
– Clean ring groove before checking.
dimensions in mm
1st compression ring 0.06 ... 0.09 0.25
2nd compression ring 0.05 ... 0.08 0.25
Oil scraper ring 0.03 ...0.06 0.15
Checking cylinder bores
AG. Volkswagen AG d
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spec
es, in part or in w
t to the co
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♦ Inside caliper 50 … 100 mm

– Take measurements at 3 positions in both transverse -A- and
nf
ercia
longitudinal -B- directions, as illustrated. Difference between

orm
actual and nominal diameter max. 0.10 mm.

m
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62
Prote AG.
Rep. gr.13 - Crankshaft group
Note
Cylinder bores must not be measured when cylinder block is

mounted on a repair stand with engine support bracket - VW 540- ,
as measurements may then be incorrect.
Piston installation position and allocation of piston to cylinder

Piston in cylinders 1 and 2:
Larger inlet valve recess -arrows- towards flywheel.
Piston in cylinders 3 and 4:
Larger inlet valve recess -arrows- towards belt pulley end.
Note
♦ New piston allocation to cylinders is shown by a coloured

marking on piston crown.
♦ Piston for cylinders 1 and 2: marked 1/2
♦ Piston for cylinders 3 and 4: marked 3/4
AG. Volkswagen AG d
agen oes
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Prote AG.

15 – Cylinder head, valve gear

1 Cylinder head
Note
♦ When installing an exchange cylinder head with fitted cam‐

shaft, the contact surfaces between the bucket tappets and
the cam must be oiled before installing the cylinder head cov‐
er.
♦ The plastic packing pieces for protecting the open valves must
not be removed until immediately before fitting cylinder head.
♦ If the cylinder head is renewed, all the coolant in the system
must also be renewed.
⇒ “1.1 Assembly overview - cylinder head”, page 64

⇒ “1.2 Removing and installing cylinder head cover”, page 67
⇒ “1.3 Removing, installing and tensioning toothed belt”,
page 70
⇒ “1.4 Removing and installing cylinder head”, page 88
⇒ “1.5 Checking compression”, page 93 .
AG. Volkswagen AG d
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1.1 Assembly overview - cylinderksw head
oes
not
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es, in part or in w
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64 Rep. gr.15 - Cylinder head, valve gear

AG. Volkswagen AG d
1 - Toothed belt guard upper wage
n oes
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part db
y V gu
ara
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ris
2 - Toothed belt ut
ho eo
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a
❑ Mark directionssof rota‐ c
ce
le
tion before removing
un
pt
an
d
❑ Check for wear
itte
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rm
ab
❑ Do not kink
pe
ility
ot
❑ Removing, installing
wit
, is n
h re
and tensioning
hole
⇒ page 70
spec
es, in part or in w
3 - 10 Nm
t to the co
❑ Renew
4 - 25 Nm
rrectness of i
5 - 100 Nm
l purpos
6 - Camshaft pulley
nform
ercia
7 - Hub
m
a
❑ With sender wheel
com
tion in
❑ Use counterhold -
r
te o
thi
T10051- to loosen and
s
iva
do
tighten.
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rp
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fo
❑ To remove, use puller -
en
ng
t.
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T10052- .
Co
Cop py
.
❑ Removing and instal‐
t rig
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8 - Rear toothed belt guard
AG.
9 - Sealing grommet
10 - Hall sender - G40-
❑ For camshaft position
❑ To remove, unbutton
sealing grommet ⇒ Item 9 (page 65) from rear toothed belt guard.
11 - Stud
❑ 15 Nm
12 - Cylinder head bolt
❑ Observe sequence when loosening and tightening ⇒ page 88 .
❑ Before installing, place washers in cylinder head ⇒ Item 4 (page 96) .
13 - Fuel return line
14 - Fuel supply line
15 - Coolant line
16 - Cylinder head cover
❑ Before fitting, thoroughly clean sealing surface of cylinder head with clean cloth.
17 - Pressure regulating valve
❑ For crankcase ventilation.
18 - To turbocharger.
19 - Cap
❑ Renew seal if damaged
20 - Seal
1. Cylinder head 65
21 - 10 Nm
❑ Observe tightening sequence ⇒ page 67 .
22 - Gasket for cylinder head cover
❑ Renew together with cylinder head cover only.
❑ Before fitting, seal transitions with “AMV 174 004 01” ⇒ page 67
23 - 20 Nm
24 - Lifting eye
25 - Unit injector
26 - 10 Nm
27 - Central connector
❑ For unit injector
28 - From brake servo
29 - Tandem pump
❑ For fuel and vacuum supply
❑ Checking ⇒ page 204
❑ Removing and installing ⇒ page 207 AG. Volkswagen AG d
agen
❑ Must not be dismantled Volksw
oes
not
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30 - Supply hose orise nte
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h
ut
❑ From fuel filter ss a ra
c
❑ White or with white marking
ce
le
un
pt
an
d

itte
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rm
ab
❑ Secure with spring-type clips
pe
ility
ot
wit
31 - Return hose
, is n
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❑ To fuel filter
hole
spec
❑ Blue or with blue marking
es, in part or in w
t to the co
❑ Secure with spring-type clips
32 - Seal rrectness of i
l purpos
❑ Renew
33 - Bracket
nform
ercia
34 - 20 Nm
m
a
com
ti
35 - Cylinder head
on in
r
te o

thi
s
iva
do
❑ After renewing, renew entire coolant.

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rp
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fo
36 - Cylinder head gasket

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t.
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op
❑ Renew C py
t. rig
gh ht
yri
❑ Note marking ⇒ page 67 . p by
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by c lksw
❑ After renewing, renew entire coolant.
cted agen
Prote AG.
37 - Glow plug
❑ 15 Nm
38 - Tensioning roller
❑ Remove engine support in order to remove and install ⇒ page 34 .
39 - 20 Nm + turn (45°)

Checking cylinder head for distortion
AG. Volkswagen AG d
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Special tools and workshop equipment required ole,
spec
♦ Straight edge
t to the co
♦ Feeler gauges
rrectne
Max. permissible distortion: 0.1 mm
ss o
Note
cial p
f inform
mer
Reworking diesel cylinder heads is not permissible.
atio
om
n
c
i
Cylinder head gasket identification
or
n thi
te
sd
va
♦ Part No. = arrow 1

i
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♦ Production control code = arrow 2 (can be disregarded)
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♦ Holes = arrow 3 . C rig
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Note
AG.
♦ Different thicknesses of cylinder head gasket are fitted de‐

pending on the piston projection. When renewing gasket,
install new gasket with same identification.
♦ Piston projection at TDC must be determined when installing
new pistons or a short engine. ⇒ page 60
1.2 Removing and installing cylinder head

cover

♦ Sealant as per ⇒ Electronic Parts Catalogue (ETKA)
1. Cylinder head 67
AG. Volkswagen AG d
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Golf 2004 ➤ , Golf Plus 2005 t➤ ho , Passat 2006 ➤ , Touran 2003 ➤
ris
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4-cylinder diesel engine (1.9
ss al engine) - Edition 12.2013 ra
c
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nl
pt
⇒ page 8 Removing
du
an
itte
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erm
– Remove engine cover. To do this, pull engine cover upwards
ab
ility
abruptly at front -arrows A- and then pull forwards out of rear
ot p
wit
fastening -arrow B-.
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
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at
do
riv
wards at -arrows-.
p
cum
for
– Remove upper toothed belt guard.
en
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t.
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– Disconnect crankcase breather hose at union on rear of t. C rig
gh ht
charge air pipe. pyri by
Vo
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by c lksw
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– Unbolt bracket from exhaust gas recirculation valve. Prote AG.
Engine codes BLS, BXJ: to remove cylinder head cover, addi‐

tionally remove:
♦ -1- upper toothed belt guard
♦ -2- intake hose
♦ -3- intake manifold flap Renew seal.
♦ -4- bolt, 8 Nm
– Remove cylinder head cover.
Cylinder head cover, engine codes: AVQ, BJB, BKC, BRU, BXE,
BXF

Cylinder head cover, engine codes: BLS, BXJ

Installing for all engine codes
Install in reverse order. In the process, note the following:
Note
♦ Renew cylinder head cover gasket and seal for bolts if dam‐
aged. AG. Volkswagen AG d
agen oes
ksw
♦ Renew seal for intake manifold flap. Engine codes BLS,byBXJ Vol not
gu
ara
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ris nte
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– Place a drop (approx. 5 mm dia.) of sealant as per ⇒ Electronic s
ce
e
Parts Catalogue (ETKA) on edges of both sealing surfaces of
nl
pt
du
an
bearing cap and cylinder head at front of engine -arrows-.
itte
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erm
ab
ility
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, is n
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spec
es, in part or in w
t to the co
rrectness of i
l purpos
Cylinder head cover, engine codes: BJB, BKC, BRU, BXE, BXF
nf
ercia
– Screw on cylinder head cover by hand in sequence -1 … 13-.
orm
m
atio
– Tighten bolts in sequence -1 … 13- to 10 Nm.
om
n in
or c
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Prote AG.
Cylinder head cover, engine codes: BLS, BXJ

– Screw on cylinder head cover by hand in sequence -1 … 13-.
– Tighten bolts in sequence -1 … 13- to 10 Nm.
1. Cylinder head 69
1.3 Removing, installing and tensioning

toothed belt
Note
♦ A revised engine support has been introduced gradually and

it is no longer necessary to remove the engine support and to
support the engine for the procedure “removing, installing and
tensioning toothed belt”.
♦ To change the tensioning roller, for both versions the engine
support must be removed.
. Volkswagen AG
gen AG d
– Determine which type of engineVol
ksupport
swa is installed in the
oesve‐
not
hicle. ed by gu
ara
is nte
or eo
-1-: Engine support bolted
au close to engine (removal necessary)
th ra
⇒ page 70 ss c
ce
le
un
pt
-2-: Engine support bolted further away from engine ► (removal
an
d
itte
not necessary) ⇒ page 81
y li
rm
ab
pe
ility
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wit
, is n
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spec
es, in part or in w
t to the co
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com
tion in
r
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1.3.1 Removing and installing toothed belt (vehicles with engine support bolted
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Prote AG.


equipment required
♦ Locking pin - 3359-
♦ Pin wrench - T10020- or
hexagon wrench
♦ Locking pin - T10115-
♦ Crankshaft stop - T10050-
♦ Torque wrench -
V.A.G 1331-
♦ Torque wrench -
V.A.G 1332-
AG. Volkswagen AG d
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ab
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es, in part or in w
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Cop py
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rig ht
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by lksw
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Prote AG.
1. Cylinder head 71
♦ Support bracket - 10-222A-

with adapters - 10-222A/1-
♦ Counterhold - T10172- with
pins - T10172/4-
(on vehicles with oval
crankshaft belt pulley)
AG. Volkswagen AG d
agen oes
olksw not
byV gu
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aut ra
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pt
du
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ab
ility
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, is n
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spec
es, in part or in w
t to the co
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nf
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orm
m
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Cop py
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rig ht
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by lksw
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Prote AG.

Note
From model year 2004, a new toothed belt tensioner is installed.

The tensioning roller has an additional hexagon hole -arrow-. To
tension and release toothed belt, use Allen key instead of pin
wrench - T10020- . This does not aalter the
gen AG
. Voprocedure.
lkswagen AG
do w es n
olks ot g
byV ua
Removing ris
ed ran
tee
tho or
au ac
ss
ce
Note
e
nl
pt
du
an
itte
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Adjustment work on toothed belts must be performed only on cold
erm
ab
engines, as the indicator position on the tensioning element varies
ility
ot p
depending on the engine temperature.
wit
, is n
h re
hole
spec
– Remove engine cover. ⇒ page 8
es, in part or in w
t to the co
– Unbolt coolant expansion tank; coolant hoses remain connec‐
ted.
rrectness of i
– Remove tensioning element for poly V-belt.
l purpos
nform
ercia
– Remove charge air pipe between charge air cooler and turbo‐
m
charger. ⇒ page 229
at
om
ion
c
– Carefully cover or seal open ends.

in t
or
his
ate
– Remove belt pulley with vibration damper.

do
priv
cum
or
– Remove lower and centre parts of toothed belt guard.

f
en
ng
t.
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op
Golf, Golf Plus, Touran C py
t. rig
gh ht
pyri by
Vo
co
– Set up support bracket - 10-222A- with adapters - 10-222A/
by lksw
cted agen
22- and support engine in installation position.
Prote AG.
Note
If toothed belt is to be removed in order to remove cylinder head,

set up support bracket - 10-222A- with higher adapters - 10-222A/
13- . This will provide the space necessary for removing the cyl‐
inder head.
Passat:
– Set up support bracket - 10-222A- with adapters - 10-222A/1-

and support engine in installation position.
Passat: If the toothed belt has to be taken off for removal of the
cylinder head.
1. Cylinder head 73
Note
G. Volkswagen
Both lifting eyes for the support are located
lksw on the cylinder head, es not
agen
A AG do
so an additional spindle -A- with bracket
db
y V to support the engine
o gu
ara
must be secured on the cylinderorblock.
ise nte
e
th or
s au ac
– Set up support bracket - 10-222A- with adapters - 10-222A/1- s
ce
le
and support engine in installation position with spindles -B-

un
pt
an
d
and -C-.
itte
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rm
ab
pe
ility
ot
wit
Note
, is n
h re
hole
spec
♦ Spindle -A- hangs loose.
es, in part or in w
t to the co
♦ Unscrew filler neck for window wash system.
♦ Unbolt coolant expansion tank and lay to side (hoses remain
rrectness of i
connected).
l purpos
– Pull fuel filter out of bracket.

– Unscrew filler neck for window wash system.
nform
mercia
a
– Unbolt fuel filter bracket from engine mounting -arrows-.
com
tion in
r
– Unbolt coolant expansion tank and lay to side (hoses remain

te o
thi
connected).
s
iva
do
r
rp
cum
fo
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
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co lksw
by
cted agen
Prote AG.
– Remove securing bolts between assembly mounting and en‐

gine bracket and between assembly mounting and body
-arrows- and remove complete assembly mountings.
Note
♦ The assembly mounting may only be removed if the engine is

supported with support bracket - 10-222A- !
♦ The engine bracket must be loosened only when the assembly
mounting has been removed.
WARNING
When raising and lowering engine using support bracket -

10-222A- , ensure that no components or hoses are damaged,
strained or torn off.

– Raise engine with support bracket - 10-222A- until both upper

bolts of engine bracket can be loosened.
– Lower engine with support bracket - 10-222A- until both lower
bolts of engine bracket can be loosened.
– Remove refrigerant line securing clamp from longitudinal
member.
– Remove engine support.
– Turn crankshaft to TDC No. 1 cylinder.
Note
Gradual introduction of oval crankshaft toothed belt pulleys.

When installing this toothed belt pulley, the crankshaft stop -
T10100- must be installed to determine the TDC position instead
of crankshaft stop - T10050- . Observe identification characteris‐
tics -arrows-.
lkswage es n
o ot g
b yV ua
Characteristics of crankshaft toothed belt pulley ir se
d ran
tee
th o
u or
A = round toothed belt pulley, lock using crankshaft
ss
a stop - ac
T10050- , TDC marking at 12 o'clock
ce
e
nl
pt
du
an
B = oval belt pulley, lock using crankshaft stop - T10100- . TDC
itte
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marking at 1 o'clock
erm
ab
ility
ot p
Vehicles with round crankshaft pulley
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
t. rig
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pyri by
Vo
co lksw
by
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Prote AG.
1. Cylinder head 75
Note
Turn crankshaft until marking on crankshaft pulley and tooth seg‐

ment of camshaft pulley is on top. The marking on the rear toothed
belt guard must align with the marking on the camshaft sender
wheel -arrow-. agen
AG. Volkswagen AG d
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olksw not
V gu
d by ara
– Lock hub using locking pin - 3359- . To do this, slide olocking
ris
e nte
eo
pin through the free elongated hole on left into holeauin
t cylinder
h
ra
head. ss c
ce
le
un
pt
– Lock crankshaft toothed belt pulley with crankshaft stop -
an
d
itte
T10050 - . To do this, push crankshaft stop into teeth of belt
y li
erm
ab
pulley from face side.
ility
ot p
wit
is n
h re
ole,
Note
spec
t to the co
The marks on the crankshaft toothed belt pulley and the crank‐
shaft stop must align. When doing this, the pin of the crankshaft
stop must engage in the drilling of sealing flange.
rrectne
Vehicles with oval crankshaft pulley
ss
o
cial p
f inform
mer
atio
m
Note
o
n
c
i
or
n thi
te
sd
iva
o
r

p
cum
r
fo
en
ng
t.
wheel -arrow-.
yi Co
Cop py
t. rig
gh ht
yri by
– Lock hub using locking pin - 3359- . To do this, slide locking op Vo
by c lksw
pin through the free elongated hole on left into hole in cylinder cted agen
Prote AG.
head.
T10100- . To do this, push crankshaft stop into teeth of belt
pulley from face side.
Note

– Mark direction of rotation of toothed belt.

– Loosen securing bolts -1- of camshaft pulley until the camshaft

pulley can be moved within the elongated holes.
– Loosen tensioning roller securing nut.
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
– Turn pin wrench - T10020- anti-clockwise until toothed belt
wit
is n
tensioning roller can be locked with locking pin - T10115- .
h re
ole,
spec
t to the co
Note
A hexagon key can be used to tension or relieve tension on the
rrectne
tensioning roller.
ss o
cial p
f inform
mer
atio
om
n
c
– Now turn 2-hole pin wrench - T10020- clockwise to stop and
i
or
n thi
e
tighten securing nut -1- hand-tight.

t
sd
iva
o
pr
c
– Remove toothed belt first from coolant pump and then from
um
r
fo
en
remaining pulleys.
ng
t.
yi Co
op py
Installing t. C rig
gh ht
pyri by
Vo
• Camshaft locked with locking pin - 3359- .
co lksw
by
cted agen
Prote AG.
• The crankshaft is locked with crankshaft stop - T10050- or
crankshaft stop - T10100- .
• Tensioning roller locked with locking pin - T10115- and se‐
cured to right stop.
Note
Adjustment work on toothed belts must be performed only when

the engine is cold, as the indicator position on the tensioning el‐
ement varies depending on the engine temperature.
– Turn camshaft pulley in its elongated holes to centre position

-arrows-.
– Fit toothed belt onto crankshaft toothed belt pulley, tensioning
roller, camshaft toothed belt pulley and idler roller.
– Then fit toothed belt on coolant pump toothed belt pulley.
1. Cylinder head 77
Note
Ensure that tensioning roller seats correctly in rear toothed belt

guard -arrow-.
– Loosen tensioning roller securing nut and pull out locking pin
- T10115- .
– Now carefully turn tensioning roller clockwise using pin wrench

- T10020- until indicator is in middle of gap in the base plate
-arrow-.
Ensure that securing nut does not turn as well.
– Hold tensioning roller in this position and tighten tensioning
roller securing nut as follows: 20 Nm and 45° (1/8 turn) further.
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
– Fit counterhold - T10172- with pins - T10172/4- as shown.
erm
ab
Press counterhold - T10172- in direction of arrow, keeping
ility
ot p
camshaft toothed belt pulley under tension.
wit
, is n
h re
– In this position, tighten camshaft toothed belt pulley securing
hole
spec
bolts -1- to 25 Nm.
es, in part or in w
t to the co
– Remove locking pin - 3359- and crankshaft stop - T10050- .
– Turn crankshaft two rotations in engine direction of rotation
until crankshaft is just before TDC No. 1 cylinder.
rrectness of i
Vehicles with round crankshaft pulley
l purpos
nform
ercia
– Lock hub with locking pin - 3359- whilst turning engine in di‐
m
at
om
rection of rotation.
ion
c
in t
or
– Check whether crankshaft can be locked with crankshaft stop

his
ate
- T10050- .
do
priv
cum
or
If crankshaft cannot be locked:

f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

– Loosen securing bolts -1- for camshaft toothed belt pulley.
– Turn crankshaft slightly opposite direction of engine rotation

until pin of crankshaft stop is positioned just before hole in
sealing flange -arrow-.
– Now turn crankshaft in engine direction of rotation until crank‐
shaft stop pin engages in sealing flange whilst turning.
Vehicles with oval crankshaft pulley
– Lock hub with locking pin - 3359- whilst turning engine in di‐
rection of rotation.
– Check whether crankshaft can be locked with crankshaft stop
n AG. Volkswagen AG
- T10100- . wage does
olks not
yV gu
db ara
If crankshaft cannot be locked: rise nte
tho eo
au ra
c
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos

nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
1. Cylinder head 79

until pin of crankshaft stop is positioned just before hole in n AG. Volkswagen A
sealing flange -arrow-. olks
wage
G do
es n
o V t gu
by ara
– Now turn crankshaft in engine direction of rotation
ris
ed until crank‐ nte
shaft stop pin engages in sealing flange whilst
utho turning. eo
ra
a c
ss
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
– Fit counterhold - T10172- with pins - T10172/4- as shown.
Press counterhold - T10172- in direction of arrow, keeping
camshaft toothed belt pulley under tension.
rrectne
bolts -1- to 25 Nm.
ss
o
cial p
f inform
mer
atio
om
n
c
– Repeat check.
i
or
n thi
te
sd
a
– Attach engine bracket to cylinder block ⇒ page 36 .

iv
o
pr
cum
r
fo
en
ng
t.
yi Co
Note . Cop py
rig
ht ht
rig by
py
Before installing assembly mounting, tighten all engine bracket co Vo
by lksw
bolts to specified torque.
cted agen
Prote AG.
– Install assembly mounting between engine and body (renew

securing bolts).
Tightening torque of M 8 bolts: 20 Nm + (90°) turn further
Tightening torque of M 10 bolts: 40 Nm + (90°) turn further
– Bolt engine assembly mounting to engine bracket by bringing
contact surfaces together using support bracket - 10-222A- .
Specified torque: 60 Nm + turn (90°) further
– Install centre and lower parts of toothed belt guard.
– Install belt pulley vibration damper (renew securing bolts).
Tightening torque: 10 Nm + (90°) turn further
– Install upper toothed belt guard.
– Install front right wheel housing liner.
– Install coolant expansion tank.

– Bolt fuel filter bracket to engine mounting to 8 Nm torque

-arrows-.
– Engage fuel filter in bracket.
– Bolt on filler neck for window wash system.
– Fit engine cover.
1.3.2 Removing and installing toothed belt (vehicles with engine support bolted
further away from engine)
Note
♦ A revised engine support has been introduced gradually and it is no longer necessary to remove the engine
support and to support the engine for the procedure “removing, installing and tensioning toothed belt”.
♦ To change the tensioning roller, for both versions the engine support must be removed.

equipment required
♦ Diesel injection pump lock‐
ing pin - 3359-
♦ Locking pin - T10060 A-
♦ Counterhold - T10172- n AG. Volkswagen AG do
swage es n
♦ Special wrench, long reach byV
olk ot g
ua
- T10264- ir se
d ran
tee
tho
or
♦ Locking tool - T10265- ss
au ac
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
1. Cylinder head 81
Removing
– Remove engine cover. ⇒ page 8 To do this, pull engine cover
upwards abruptly at front -arrows A- and then pull forwards out
of rear fastening -arrow B-.
– Remove two-piece engine cover panel ⇒ page 8 .
WARNING
♦ In extreme cases, the fuel lines and the fuel can reach a
temperature of 100 °C on vehicles with unit injector en‐
gine. Allow the fuel to cool down before disconnecting the
lines - danger of scalding.
♦ Wear protective gloves.
♦ Wear eye protection.
– Pull fuel supply hose -2- and fuel return

agen
Ahose
G. Vol-1-
kswaoff
genfuel
AG dlines.
o w es n
olks ot g
– Pull off coolant line -3-. byV ua
ed ran
ris tee
– Remove bolt -1-. au
tho or
ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– Remove connecting pipe between charge air cooler and intake

connecting pipe, to do this, lightly lift retaining clips -arrows-.
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

– Disconnect fuelwsupply
gen AGline -3- and return
. Volkswagen AG
does line -2- by pulling
s a
release tabs.
y Volk not
gu
b ara
ed n
– Removetho
ris fuel filter »screwed filter« and lay it with hoses
tee
or
to side
-arrow-.
s au ac
s
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
– Pull fuel filter »inserted filter« out of bracket -arrow-.
rrectne
– Unscrew bolt at filler neck -2- for windscreen washer system
reservoir.
ss
– Unscrew bracket -3- for fuel filter.
o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
op py
– Disconnect electrical connector on coolant expansion tank
. C rig
ht ht
rig
-1-. py by
co Vo
by lksw
cted agen
– Remove coolant expansion tank, coolant hoses remain con‐
Prote AG.
nected. Place it on engine.
– Remove tensioning element for poly V-belt.
– Remove upper toothed belt guard, to do this, loosen retaining

clips -arrows-.
– Remove belt pulley with vibration damper.
– Remove lower and centre parts of toothed belt guard.
1. Cylinder head 83
Note

wheel -arrow-.
– Lock hub using locking pin - 3359- . To do this, slide locking

pin through the free elongated hole on left into hole in cylinder
head.
T10100- . To do this, push crankshaft stop into teeth of belt gen AG. Volkswagen AG d
pulley from face side. Vol
ksw
a oes
not
y gu
db ara
rise nte
tho eo
Note s au ra
c
s
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
– Mark direction of rotation of toothed belt.
h re
ole,
spec
– Loosen securing bolts -1- of camshaft pulley until the camshaft
t to the co
pulley can be moved within the elongated holes.
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
– Loosen tensioning roller securing nut -1-.

en
ng
t.
yi Co
op
– Turn eccentric of tensioning roller anti-clockwise -arrow- using C py
t. rig
socket - T10264- , until the tensioning roller can be locked with
gh ht
pyri by
locking tool - T10265- .
co Vo
by lksw
cted agen
Prote AG.

– Now turn tensioning roller eccentric clockwise -arrow- onto

stop and tighten securing nut -1- hand-tight.
– Remove toothed belt first from coolant pump and then from
remaining toothed belt pulleys.
Installing
• Camshaft locked with locking pin - 3359- .
• Crankshaft locked with crankshaft
Volkswa
stop - T10100- .
AG. gen AG
agen do
• Tensioning rollerollocked
ksw with locking pin - T10265-
es n
ot g and se‐
yV
cured to right
se
d stop with securing nut.
b ua
ran
ri tee
utho or
a ac
ss
Note
ce
le
un
pt
an
d
itte
Adjustment work on toothed belts must be performed only on cold
y li
erm
ab
engines, as the indicator position on the tensioning element varies
ility
ot p
depending on the engine temperature.
wit
is n
h re
ole,
spec
– Turn camshaft pulley in its elongated holes to centre position

-arrows-.
t to the co
– Guide toothed belt through gap between engine support and
engine.
rrectne
– Fit toothed belt onto crankshaft toothed belt pulley, tensioning
roller, camshaft toothed belt pulley and idler roller.
ss o
cial p
f
– Then fit toothed belt on coolant pump toothed belt pulley.
inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
Note
yi Co
Cop py
t. rig
gh ht
yri
Ensure that tensioning roller seats correctly in rear toothed belt
p by
co Vo
guard -arrow-.
by lksw
cted agen
Prote AG.
– Remove locking pin - T10265- from tensioning roller.

– Loosen tensioning roller securing nut -1-.
– Turn eccentric of tensioning roller clockwise -arrow- using

special wrench, long reach - T10264- until indicator -2- is in
middle of gap in base plate.
Note
Ensure that securing nut does not turn as well.
– Hold tensioning roller in this position and tighten tensioning

roller nut to 20 Nm + turn 45° further.
1. Cylinder head 85
– Fit counterhold - T10172- with pin - T10172/4- as shown in

illustration, and keep the toothed belt under tension on pulling
side, by pressing in -direction of arrow-.
– Tighten bolts -1- of camshaft toothed belt pulley to 25 Nm.
until the crankshaft is just before TDC again.
– Lock hub of camshaft with locking pin - 3359- whilst turning

engine in direction of rotation.
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
– Check whether crankshaft can be locked with crankshaft stop h re

hole
- T10100- . spec
es, in part or in w
If crankshaft cannot be locked:

t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.


until pin of crankshaft stop is positioned just before hole in
sealing flange -arrow-.
– Now turn crankshaft in engine direction of rotation until crank‐
shaft stop pin engages in sealing flange whilst turning.
AG. Volkswagen AG d
agen oes
olksw not
– Fit counterhold - T10172- dwith by pins - T10172/4- as shown. guar
V
an
Press counterhold - T10172-ris
e
in direction of arrow, keeping tee
ho
camshaft toothed belt au pulley under tension.
t or
ac
ss
ce
le
un
pt
bolts -1- to 25 Nm.
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
– Repeat check and adjustment if necessary.
t to the co
– Install centre and lower parts of toothed belt guard.
– Install belt pulley vibration damper (renew securing bolts).
rrectne
Tightening torque: 10 Nm + (90°) turn further
s
s o
cial p
f i
– Install upper toothed belt guard.
nform
mer
– Install connecting pipe between charge air cooler and intake

atio
m
connecting pipe.
o
n
c
i
or
n thi
– Install front right wheel housing liner.

te
sd
iva
o
r
– Install coolant expansion tank.

p
cum
r
fo
en
ng
t.
yi Co
op
– Bolt fuel filter bracket to engine mounting to 8 Nm torque C py
t. rig
-arrows-. gh ht
pyri by
Vo
o
by c lksw
– Engage fuel filter in bracket. Prote
cted AG.
agen
– Bolt on filler neck for window wash system.

1. Cylinder head 87
1.4 Removing and installing cylinder head
Note
♦ From 05.05 a modified engine support has been introduced, it

is no longer necessary to support the enginewfor the
agen
AGprocedure
. Volkswagen AG
does
“removing and installing the cylinder head”.
yV
olks not
gu b ara
ed
♦ -1-: Engine support ► 05.05 (support
tho
ris necessary) nte
e or
au ac
♦ -2-: Engine support 06.05 ► (support
ss not necessary)
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos

equipment required
nf
ercia
o
♦ Drip tray - V.A.G 1306- or
rm
m
atio
drip tray - VAS 6208-
om
n in
c
♦ Torque wrench -
or
thi
e
V.A.G 1331-
t
sd
iva
o
r
rp
cu
♦ Torque wrench -
o
m
f
en
ng
V.A.G 1332-
t.
yi Co
Cop py
♦ Hand vacuum pump with
t. rig
gh ht
yri
accessories - V.A.G 1390- p by
co Vo
by lksw
cted agen
♦ Water drainage container - Prote AG.
V.A.G 1390/1-
♦ Retainer - T10014- (only
vehicles ► 05.05)

♦ Support bracket - 10-222A- with adapters - 10-222A/13- (only

vehicles ► 05.05)
Note
♦ From 05.05 a modified engine support has been introduced, it

is no longer necessary to support the engine for the procedure
“removing and installing the cylinder head”.
♦ -1-: Engine support ► 05.05 (support necessary)
♦ -2-: Engine support 06.05 ► (support not necessary)
♦ All cable ties which are opened or cut through when cylinder
head is removed must be replaced in the same position when
cylinder head is installed.
WARNING
When doing any repair work, especially wagein the engine compart‐
ment, pay attention tolksthe n AG. Volksdue
following to theocramped
n AG d
condi‐
wage es n
tions: by Vo ot g
ua
d ran
ise
♦ Route ualltho the various lines (e.g. for fuel, hydraulics, acti‐
r tee
or
vatedss charcoal filter system, coolant and refrigerant, brake
a ac
ce
le
un
sitions.
pt
an
d
itte
y li

erm
ab
hot components.
ility
ot p
wit
is n
h re
ole,
spec
1.4.1 Removing
t to the co
Note
rrectne
Before removing cylinder head, extract fuel using hand-operated

ss
vacuum pump with accessories - V.A.G 1390- and water drainage

o
cial p
container - V.A.G 1390/1- .

inform
mer
atio
– Remove engine cover panel ⇒ page 8 .

om
n
c
i
or
Golf, Golf Plus, Touran

thi
te
sd
va

i
o
pr
cum

r
fo
en
ng
head .
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
c by lksw
cted agen
pipe.
Prote AG.
1. Cylinder head 89
of mounting.
on cylinder head.
. Volkswage
– Before removing cylinder gen AGextract fuel
ahead, from
n AG d
oetandem pump
lksw s no
using hand-operated by Vovacuum pump with accessoriest gu - V.A.G
a
1390- and waterris drainage container - V.A.G 1390/1-
ed ran
tee
⇒ page 204au
t.
ho or
a
ss c
– Pull fuel filter module upwards out of bracket and lay it with
ce
e
nl
hoses to side.
pt
du
an
itte
y li
erm
ab
ility
ot p
– Remove turbocharger support and oil return from turbocharg‐
wit
, is n
er.
h re
hole
spec
– Remove oil supply line and lay it to side ⇒ page 118 .
es, in part or in w
t to the co
Note
rrectness of i
From 05.05 a modified engine support has been introduced, it is
l purpos
no longer necessary to remove the engine support and supporting

the engine for the procedure “removing, installing and tensioning
toothed belt” ⇒ page 70
nform
mercia
at

om
ion
c
in t
– Remove toothed belt tensioning roller.

or
his
ate
do
riv
– Install hub for camshaft pulley ⇒ page 101 , Removing and

p
cum
installing camshaft.
for
en
ng
t.
yi Co
op
– Remove rear toothed belt guard securing bolts -2- and -4-.
C py
ht. rig
rig ht
py by
– Unscrew Hall sender - G40- -3-.
co Vo
by lksw
cted agen
Prote AG.
– Remove exhaust gas recirculation connecting pipe.
– Pull off or disconnect all other electrical connections from cyl‐
inder head as necessary and lay to one side.
– Separate all connection, coolant, vacuum and intake hoses
from cylinder head.
Golf, Golf Plus Touran: Vehicles ► 05.05
Note
Both lifting eyes for the support are located on the cylinder head,
so an additional bracket for supporting the engine must be se‐
cured on the cylinder block.

– Screw retainer - T10014- into threaded hole above coolant

pump and tighten to 20 Nm.
– Lift engine slightly using spindle -A- until spindle -B- is relieved.
– Unhook spindle -B- and push it to side.
Volkswa AG. gen AG
agen does
Passat: VehiclesVo►lks05.05
w not
gu
by ara
ed nte
oris eo
th
au ra
ssNote c
ce
e
nl
pt
du
Both lifting eyes for the support bracket are located on the cylinder
an
itte
head. Therefore, an additional spindle with bracket must be se‐
y li
erm
ab
cured on the cylinder block to support the engine.
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
– Screw retainer - T10014- into threaded hole above coolant
l purpos
pump and tighten to 20 Nm.

– Lift up engine slightly via spindle -A-.
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Once spindles -B- and -C- are no longer under tension, unhook
them and slide them to one side.
For vehicles 06.05 ►
– Remove tensioning roller securing nut for toothed belt
– Remove cylinder head cover. ⇒ page 67
1. Cylinder head 91
– Maintain sequence when loosening cylinder head bolts.

– Lift cylinder head slightly and remove from engine laterally
past toothed belt guard.
Note
The cylinder head must be guided carefully to prevent damage.
1.4.2 Installing
Note
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♦ In case of repair, carefully remove
ut
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gasket remains from cylin‐ eo
der head and cylinder block. ss a Ensure that no long scores or ra
c
scratches are made on the surfaces. When using abrasive
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paper do not use a grade less than 100.
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♦ Carefully remove remains of emery and abrasives.
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♦ Handle gasket very carefully. Damage to the silicone coating
es, in part or in w
or the indented area will lead to leaks.
t to the co
– Turn crankshaft to TDC marking before fitting cylinder head.
rrectness of i
– Turn crankshaft opposite engine direction of rotation until all
pistons are approximately equally placed below TDC.
l purpos
– Fit cylinder head gasket.

nform
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Note
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Note identification on cylinder head gasket ⇒ page 67 .

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– Fit cylinder head and tighten all cylinder head bolts hand-tight.
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– Tighten cylinder head in four stages in the indicated sequence

as follows:
1- Tighten initially with torque wrench:
Stage I = 35 Nm
Stage II = 60 Nm
2- Turn further with rigid spanner:
Stage III = + (90°) turn further
Stage IV = + (90°) turn further
Note
After repair work it is not necessary to retighten the cylinder head

bolts.
Further installation is carried out in the reverse order. In the proc‐

ess, note the following:
– After tightening cylinder head, turn camshaft so that cams for

No. 1 cylinder point equally upwards. Before fitting toothed
belt, turn crankshaft in engine direction of rotation
⇒ page 70 , removing, installing and tightening toothed belt.
– Install hub for camshaft toothed belt pulley ⇒ page 101 , Re‐
moving and installing camshaft.
– Install toothed belt ⇒ page 70 .
– Install oil supply line ⇒ page 118 .
– Install noise insulation ⇒ General body repairs, exterior; Rep.
gr. 50 ; Assembly overview - Body - front .
– Install plenum chamber bulkhead ⇒ General body repairs,
exterior; Rep. gr. 50 ; Bulkhead;
agen Assembly overview
AG. Volkswagen AG d
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head . yV
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– Fill coolant system
ho
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– Carry out road
ss test and then read fault memory ⇒ page 251 .
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If ceramic glow plugs are fitted, before removing check idling

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speed smooth running control using vehicle diagnosis, testing

and information system - VAS 5051B- . The compression test is
only justified if one or more cylinders are conspicuous.
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Test prerequisite
• Engine oil temperature min. 30°C
Test procedure
– Pull off central connector for unit injectors.
Note
If ceramic glow plugs are fitted, always observe notes on remov‐

ing and installing ceramic glow plugs ⇒ page 281 .
– Remove all glow plugs or ceramic glow plugs using jointed

extension and socket - 3220- .

n AG. V4-cylinder
olkswagen AGdiesel engine (1.9 l engine) - Edition 12.2013
ks wage doe s no
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– Screw in adapter - V.A.G
ris 1381/12-
ed in place of glow plugs or rante
ceramic glow plugs.utho eo
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– Check compression using compression tester - V.A.G 1763- .
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Using the test equipment ⇒ Operating instructions.
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– Operate starter until tester shows no further pressure in‐
t to the co
crease.
Compression pressures:
rrectne
New: 25 ... 31 bar, wear limit: 19 bar
Maximum permissible difference between all cylinders: 5 bar
ss o
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mer
Note
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If ceramic glow plugs are fitted, always observe notes on remov‐
c
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or
n thi
ing and installing ceramic glow plugs ⇒ page 281 .
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– Remove glow plugs or ceramic glow plugs using jointed ex‐
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– Read fault memory of engine control unit ⇒ page 251 . Prote
cted AG.
agen
Note
Disconnecting the central connector for unit injectors causes

faults to be stored. Therefore, read fault memory and clear if nec‐
essary.
1. Cylinder head 95
2 Valve gear
Note
Cylinder heads with cracks between the valve seats may be used
without reducing engine life, provided the cracks are small and
not more than 0.5 mm wide.
⇒ “2.1 Assembly overview - valve gear”, page 96

⇒ “2.2 Checking valve guides”, page 98
⇒ “2.3 Renewing valve stem seals”, page 99agen AG. Volkswagen AG do
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1 - 20 Nm + turn (90°)
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loosening and tighten‐
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ing ⇒ page 101 , Re‐
t to the co
moving and installing
camshaft.
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2 - Rocker arm shaft
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3 - Cylinder head bolt nf
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❑ Renew
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❑ Note sequence when

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loosening and tighten‐

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4 - Washer
AG.
❑ For cylinder head bolts.

❑ Insert in cylinder head
before installing bearing
caps
5 - Bucket tappet
❑ With hydraulic valve
clearance compensa‐
tion.
❑ Set down with contact
surface facing down‐
wards.
❑ Before installing, check
camshaft axial clearance ⇒ page 98 .
❑ Oil contact surface
❑ Before removing, remove camshaft bearing caps

6 - Valve cotter
7 - Valve spring plate
8 - Outer valve spring
❑ Removing and installing: with cylinder head removed, use valve spring compressor - 2037- ; with cylinder
head installed ⇒ page 99 , Renewing valve stem seals.
9 - Inner valve spring
❑ Removing and installing: with cylinder head removed, use valve spring compressor - 2037- ; with cylinder
head installed ⇒ page 99 , Renewing valve stem seals.
10 - Valve stem seal
❑ Renew ⇒ page 99
11 - Valve guide
12 - Unit injector
13 - Cylinder head
❑ See note ⇒ page 96
14 - Seal
❑ Do not additionally oil or grease the oil seal sealing lip.
❑ Before installing, remove residual oil from camshaft journal using a clean cloth.
❑ To install, tape over groove in taper of camshaft (e.g. using Sellotape).
15 - Valves
❑ Valve dimensions ⇒ page 98
16 - Bearing shell
❑ Do not interchange used bearing
agen
AG.shells
Volkswa(mark).
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❑ Ensure that retaining
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17 - Camshaft ut
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❑ Checking axial
ss clearance ⇒ page 98 .
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❑ Check radial clearance with Plastigage; wear limit: 0.11 mm

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❑ Runout: max. 0.01 mm

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18 - Bearing cap
h re
hole
❑ Installation sequence ⇒ page 101 , removing and installing camshaft

spec
es, in part or in w
❑ When installing, seal parting surfaces of bearing caps 1 and 5 with sealant as per ⇒ Electronic Parts
t to the co
Catalogue (ETKA) ⇒ page 98 .

19 - 8 Nm + turn (90°)
rrectness of i
❑ Renew
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2. Valve gear 97
Checking camshaft axial clearance

♦ Universal dial gauge bracket - VW 387-
♦ Dial gauge
Check with bucket tappets removed and with first, third and last
bearing caps fitted.
Wear limit: max. 0.15 mm
Seal parting surfaces of bearing caps 1 and 5 with sealant
– Apply sealant as per ⇒ Electronic Parts Catalogue
AG. V(ETKA)
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thinly and evenly on surfaces -1-. Volksw not
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Be careful that no sealant gets into grooves -arrows-. pt

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Valve dimensions
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Note
Valves must not be reworked. Only lapping-in is permitted.

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Dimension Inlet valve Exhaust valve

∅a mm 35.95 31.45
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∅b mm 6.980 6.956
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♦ Universal dial gauge bracket - VW 387-
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♦ Dial gauge
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Test procedure
rrectne
– Insert new valve into guide. The end of the valve stem must
be flush with the guide. On account of differing stem diame‐
ters, only use inlet valve in inlet guide and exhaust valve in
ss
exhaust guide.
o
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f in
– Determine rock. Wear limit: max. 1.3 mm
form
mer
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– Cylinder head must be renewed if rock exceeds wear limit.
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2. Valve gear 99

equipment required
♦ Assembly tool - 2036-
♦ Puller - 3047 A-
♦ Fitting tool - 3129-
♦ Valve lever - VW 541/1A-
♦ Thrust piece - VW 541/5-
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2.3.1 Removing
rrectness of i
(With cylinder head installed)

l purpos
– Remove camshaft. ⇒ page 101

nf
ercia
– Remove bucket tappets and place them with the contact sur‐
or
face downwards. When doing this, ensure that the tappets are
m
m
atio
not interchanged.
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– Set piston of respective cylinder to top dead centre (TDC).

thi
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– Insert valve assembly device - 2036- and adjust mounting to

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Note
The valves are supported by the piston crown.

– Pull off valve stem seals using puller - 3047 A- . AG. Volkswagen AG d
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2.3.2 Installing
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– Place the plastic sleeve -A- supplied on the respective valve
stem. This will prevent the new valve stem seal -B- being
l purpos
damaged.
– Insert new valve stem seal in fitting tool - 3129- .
nform
ercia
– Lubricate sealing lip of valve stem seal and carefully push on

m
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valve guide.
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2.4 Removing and installing camshaft

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2. Valve gear 101


equipment required
♦ Counterhold - T10051-
AG. Volkswagen AG d
♦ Puller - T10052- ksw
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♦ Torque wrench (5... 50 Nm) ise
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- V.A.G 1331- uthor eo
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♦ Torque wrench (40... s
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200 Nm) - V.A.G 1332-

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♦ Sealant as per ⇒ Electronic
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2.4.1 Removing
– Remove securing bolts for camshaft toothed belt pulley -1-.
– Pull camshaft toothed belt pulley off hub.

– Loosen hub securing bolt -1-.

– To do this, use counterhold - T10051- .
– Loosen hub securing bolt about 2 turns.
lkswage es n
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– Apply puller - T10052- and screw securing bolts -1- into hub.
nl
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– Apply tension to hub by evenly tightening puller until hub sep‐
erm
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arates from taper of camshaft.
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Note
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es, in part or in w
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When doing this, hold puller with 30 mm spanner.
– Remove hub from taper of camshaft.
rrectness of i
– Remove cylinder head cover.
l purpos
– Mark rocker arm shafts using a permanent felt tip marker to
nf
ercia
prevent interchanging. This will prevent having to perform ba‐
orm
sic settings of unit injectors -arrows-.
m
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– Remove rocker arm shafts.
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– Remove tandem pump ⇒ page 204 .
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– First remove bearing caps 5, 1 and 3. Then loosen bearing

caps 2 and 4 alternately and diagonally.
– Remove camshaft.
2. Valve gear 103

Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003
gen AG
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wagen AG
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4-cylinder diesel engine (1.9 l engine) - Edition y12.2013
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2.4.2 Installing th e or
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♦ When camshaft is installed, No. 1 cylinder cams must point
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♦ Do not interchange used bearing shells (mark).
es, in part or in w
t to the co
♦ When installing the camshaft, ensure proper seating of retain‐
ing lugs in bearing caps and cylinder head.
♦ Before installing bearing caps, ensure that cylinder head bolt
rrectness of i
washers are inserted in the cylinder head.
l purpos
– Oil bearing shell running surfaces.
nform
ercia
– Install bearing caps 2 and 4 using new bolts.

m
a
– Tighten bearing caps 2 and 4 in diagonal sequence alternately
com
tion in
to 8 Nm + (90°) turn further.
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– Install bearing caps 5, 1 and 3 using new bolts.
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⇒ page 98 .
♦ Bearing cap 5 must be flush with outer edge of cylinder head,
otherwise leaks can occur at the tandem pump.
– Tighten bearing caps 5, 1 and 3 likewise to 8 Nm + (90°) turn

further.
– Install camshaft oil seal. ⇒ page 105
– Install injector rocker arm shafts with new securing bolts and
tighten, first the inner -2- and then the outer -1-, evenly and in
diagonal sequence to 20 Nm + (90°) turn further.
– Fit hub onto camshaft.
– Tighten hub securing bolt -1- to 100 Nm.

– To do this, use counterhold - T10051- .

– Push camshaft toothed belt pulley onto hub.
Note AG. Volkswagen AG d

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– Align camshaft toothed belt pulley at centre of elongated
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– Lock hub using locking pin - 3359- .
spec
– Install and tighten toothed belt ⇒ page 70 .
t to the co
– Screw new adjustment screws into rocker arms hand-tight and
fit lock nut.
rrectne
– Fit dial gauge onto adjustment screw of unit injector as shown.
ss
– Turn crankshaft in direction of engine rotation until roller of
o
cial p
f i
rocker arm is located at tip of drive cam. Roller side
nform
-arrow A- positioned at highest point, dial gauge -arrow B-
mer
positioned at lowest point.
atio
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i
– Remove dial gauge.
or
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– Now turn the adjuster screw into rocker arm until significant
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– Turn adjustment screw 180° back off stop.
AG.
– Hold adjuster screw in this position and tighten lock nut to 30

Nm.
– Install tandem pump ⇒ page 204 .
– Install cylinder head cover.
Note
When new bucket tappets have been installed the engine must
not be started for about 30 minutes. The hydraulic compensation
elements must settle (otherwise valves will strike pistons).
2.5 Removing and installing camshaft oil seal
2. Valve gear 105

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♦ Oil seal extractor - 3240-
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♦ Bolt M12×1.5 × 65
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2.5.1 Removing
– Remove camshaft toothed belt pulley and hub ⇒ page 101 ,
Removing and installing camshaft.
– Unscrew inner part of oil seal extractor - 3240- two turns (ap‐
prox. 3 mm) out of outer part and lock with knurled screw.
– Lubricate threaded head of oil seal extractor - 3240- , place it
in position and exerting firm pressure, screw it as far as pos‐
sible into oil seal.
– Loosen knurled screw and turn inner part against camshaft
until oil seal is pulled out.

2.5.2 Installing
Note
The oil seal sealing lip must not be additionally oiled or greased.
– Remove oil residue from camshaft journal using a clean cloth.

– Tape over groove in taper of camshaft (e.g. with Sellotape).
– Fit oil seal carefully on camshaft.
– Press in oil seal with press piece of fitting tool - 10-203- and
bolt M12 -5 x 65 onto stop.
– Install and tighten toothed belt ⇒ page 70 .
AG. Volkswagen AG d
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2. Valve gear 107

17 – Lubrication
1 Engine oil
Note
The oil level must not be above the max. mark - danger of damage
to catalytic converter! Markings.
Engine oil specification ⇒ Maintenance ; Booklet 38

⇒ “1.1 Oil capacities”, page 108
⇒ “1.2 Checking engine oil level, observing differences in dip
sticks”, page 108
1.1 Oil capacities

Engine codes AVQ BJB, BKC, BRU, BXE and BXF
With oil filter change: 3.8 l AG. Volkswagen AG d
agen oes
lksw not
Without oil filter change: 3.3 bly Vo gu
ara
ed
is nte
Engine codes BLS anduthBXJ or eo
a ra
s c
With oil filter change: 4.3 l
s
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le
un
pt
Without oil filter change: 3.8 l

an
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erm
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1.2 Checking engine oil level, observing dif‐

ility
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ferences in dip sticks

wit
is n
h re
ole,
⇒ “1.2.1 Checking engine oil level”, page 108

spec
t to the co
⇒ “1.2.2 Checking engine oil level”, page 109
1.2.1 Checking engine oil level

rrectne
Check which dipstick is installed.

s
1 - Max. mark
s o
cial p
f i
2 - Min. mark
nform
mer
a - Area above hatched field up to max. mark: do not refill with

atio
m
engine oil!
o
n
c
i
or
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b - Oil level within hatched field: Can be topped up with engine

te
sd
a
oil.
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pr
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c - Area from min. mark up to hatched field: Must be topped up,

en
ng
t.
yi
max. 0.5 l of engine oil!
Co
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co Vo
by lksw
cted agen
Prote AG.
108 Rep. gr.17 - Lubrication

1.2.2 Checking engine oil level

1 - Min. mark
2 - Max. mark
a - Area of min. mark: top-up with max. 0.5 l of engine oil!
b - Oil level in middle range: can be topped-up with engine oil.
c - Area of max. mark: do not add engine oil!
AG. Volkswagen AG d
agen oes
olksw not
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ss c
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un
pt
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, is n
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spec
es, in part or in w
t to the co
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nform
mercia
a
com
tion in
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Cop py
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Vo
co lksw
by
cted agen
Prote AG.
1. Engine oil 109

2 Parts of lubrication system
Caution
Finding metal shavings or a large quantity of small metal par‐

ticles during engine repair could indicate that the crankshaft
bearings or conrod bearings are damaged. To prevent this
from causing further damage, perform the following repairs:
Thoroughly clean oil channels
Renew engine oil cooler
Renew oil filter element
⇒ “2.1 Assembly overview - oil pump, sump”, page 110

⇒ “2.2 Removing and installing oil sump”, page 111 agen
AG. Volkswagen AG d
oes
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2.1 Assembly overview - oil pump, sump
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1 - 15 Nm
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2 - Sealing flange
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❑ With seal.
ility
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❑ Must sit on dowel
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sleeves
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ole,
spec
⇒ page 42
t to the co
❑ Insert with sealant as
per ⇒ Electronic Parts
Catalogue (ETKA)
rrectne
⇒ page 42
❑ Do not additionally oil or
ss
grease the oil seal seal‐
o
cial p
f
ing lip.
inform
mer
❑ Before installing, re‐

atio
move oil residue from

om
crankshaft journal using

c
i
or
a clean cloth.
thi
te
sd
va
❑ Renewing crankshaft oil

i
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pr
cum
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seal - belt pulley end

fo
en
ng
⇒ page 40 .
t.
yi Co
Cop py
t.
3 - Chain tensioner with ten‐
rig
gh ht
yri by
sioning rail, 15 Nm op Vo
by c lksw
cted agen
❑ When installing, preten‐ Prote AG.
sion spring and fit.
4 - Oil dipstick
❑ The oil level must not be
above the max. mark!
❑ Markings ⇒ page 108 .
5 - Piston fitting tool
6 - Guide tube
7 - Dowel sleeves
8 - O-ring
❑ Renew

9 - 15 Nm
10 - Suction line
❑ Clean strainer if soiled AG. Volkswagen AG d
agen oes
11 - Baffle plate olksw not
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12 - 15 Nm rise nte
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13 - 15 Nm ss c
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nl
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14 - Oil sump
du
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❑ Clean sealing surface before fitting.
erm
ab
ility
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❑ Install with sealant according to ⇒ Electronic Parts Catalogue (ETKA)
wit
, is n
h re
hole
spec
15 - Oil drain plug, 30 Nm
es, in part or in w
t to the co
❑ Renew
16 - 10 Nm
rrectness of i
17 - Oil level and oil temperature sender - G266-
l purpos
❑ Black 3-pin connector

18 - Seal
nf
ercia
❑ Renew
orm
m
atio
19 - Oil pump
om
n in
c
❑ With 12 bar pressure relief valve

or
thi
te
sd
❑ Before installing, check that both dowel sleeves for centring oil pump on cylinder block are fitted.
iva
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cu
❑ Renew if running surfaces and gears are scored.
o
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t.
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20 - Chain sprocket for oil pump
Co
Cop py
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21 - Bracket
ht
pyri by
Vo
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by
❑ For oil level/temperature sender wiring harness Prote
cted AG.
agen
22 - 20 Nm + turn (90°)
❑ Renew
23 - Chain
24 - 25 Nm
❑ Insert without sealant
25 - Oil spray jet
❑ For piston cooling.
Note
When renewing the oil spray jet, en‐

sure correct allocation to piston ⇒
ETKA (Electronic Parts Catalogue)
2.2 Removing and installing oil sump

2. Parts of lubrication system 111

♦ Special wrench, long reach XZN 6 - T10058-
♦ Hand drill with plastic brush attachment AG. Volkswagen AG d

agen oes
♦ Sealant as per ⇒ Electronic Parts Catalogue (ETKA) olksw not
y V gu
d b ara
ise nte
♦ Hand drill with plastic brush attachment thor eo
au ra
♦ Eye protection ss c
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nl
pt
du
♦ Flat scraper
an
itte
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ab
2.2.1 Removing
ility
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hole
spec
es, in part or in w
– Drain engine oil.
Note t to the co
rrectness of i
Observe environmental regulations for disposal.

l purpos
– Pull 3-pin connector off oil level and oil temperature sender -
nf
ercia
G266- .
rm
m
atio
m
– Remove sump.
o
n in
or c
– Loosen sump with light blows of a rubber headed hammer if

thi
te
sd
a
necessary.
iv
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rp
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o
– Remove sealant residue from cylinder block with a flat scraper.

f
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

– Remove sealant residue on sump with a rotating brush, e.g.

an electric hand drill with a plastic brush attachment (wear eye
protection).
– Clean sealing surfaces. They must be free of oil and grease.
2.2.2 Installing
Note
♦ Observe expiry date of sealing compound.

♦ The sump must be installed within 5 minutes of applying sili‐
cone sealing compound.
– Cut off tube nozzle at forward marking (∅ of nozzle approx. 3

mm).
– Apply silicone sealing compound, as shown, to clean sealing
surface on sump. Sealant bead must be
♦ 2 …3 mm thick
♦ Run bead along inner side of bolt holes -arrows-.
lkswage es n
o ot g
yV ua
Note ir se
d b ran
tee
tho
u or
a ac
The sealant bead must not be thicker, otherwise
ss excess sealing
compound will enter the oil sump and may block the oil suction
ce
le
un
line strainer. pt
an
d
itte
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erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
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te
sd
iva
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pr
cum
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fo
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t.
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Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.
2. Parts of lubrication system 113

– Apply silicone sealing compound bead as shown to the clean olkswagen AG

sealing surface of the sump. (The figure shows the AG. Vof
swposition
agen does
the sealant bead on the cylinder block.) by
Volk not
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a d ran
se
– Install sump immediately and tighten all thosump bolts lightly.
ri tee
or
Ensure that sump is flush against intermediate
ss
au
plate and gear‐ ac
box flange.
ce
e
nl
pt
du
an
itte
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erm
ab
Note
ility
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wit
, is n
When installing sump with engine removed, ensure that sump is
h re
flush with cylinder block at flywheel end.
hole
spec
es, in part or in w
t to the co
– Tighten sump bolts diagonally to 15 Nm.
– Tighten bolts securing sump to gearbox to 45 Nm.
rrectness of i
l purpos
Note
Let sealing compound dry for approx. 30 minutes after installing
nform
ercia
oil sump. Only then fill with engine oil.

m
at
om
ion
c
Further assembly is basically the reverse of the dismantling se‐
in t
or
quence.
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

3 Oil filter bracket, oil pressure, engine

oil cooler and oil supply line lksw
. Vo agen AG
a gen AG d
⇒ “3.1 Assembly overview - oil filter bracket
Vol and engine oil cooler”,
ksw
oes
not
gu
page 115 ed by ara
n is tee
or
⇒ “3.2 Checking oil pressure aand
ut oil pressure switch”,
h or
ac
page 116 ss
ce
e
nl
pt
⇒ “3.3 Assembly overview - oil supply line to turbocharger”, page
du
an
itte
117
y li
erm
ab
ility
⇒ “3.4 Removing and installing oil supply line to turbocharger”,
ot p
wit
page 118
, is n
h re
hole
3.1 Assembly overview - oil filter bracket and engine oil cooler
spec
es, in part or in w
t to the co
1 - Oil filter bracket
rrectness of i
2 - 15 Nm + turn (90°)
❑ Renew
l purpos
❑ First fit upper left and

lower right bolts and
nform
ercia
then tighten all four bolts

diagonally.
m
at
om
ion
3 - Seal
c
in t
or
his
e
❑ Renew
at
do
priv
c
4 - Seal
um
for
en
ng
t.
❑ Renew
yi Co
Cop py
t. rig
5 - Union, 35 Nm
gh ht
pyri by
Vo
o
by c lksw
6 - Oil supply line, 22 Nm Prote
cted AG.
agen
❑ To turbocharger.
⇒ page 118
7 - Cap, 25 Nm
8 - Seal
❑ Renew
9 - Oil filter element
❑ Ensure "Top" is upper‐
most when fitting
10 - Plug, 10 Nm
❑ If seal is leaking, nip
open and renew.
11 - Oil pressure switch - F1-
❑ 0.7 bar switch: brown.
❑ Tighten to 20 Nm.
❑ If seal is leaking, nip
open and renew.
12 - Plug, 25 Nm
13 - Seal
❑ Renew
3. Oil filter bracket, oil pressure, engine oil cooler and oil supply line 115
14 - Engine oil cooler

❑ Ensure clearance to adjacent components.
❑ See note ⇒ page 110
❑ Checking engine oil cooler for leaks ⇒ page 142
15 - Seal
❑ Renew
16 - Bracket
17 - 10 Nm
G. Volkswage
3.2 Checking oil pressure
olks
wage
nA
and oil pressure
n AG d
oes
not switch
yV gu
db ara
rise nte
tho
eo
au ra
equipment required ss c
ce
e
nl
pt
♦ Oil pressure tester -
du
an
itte
V.A.G 1342-
y li
erm
ab
ility
♦ Voltage tester -
ot p
wit
V.A.G 1527 B-
, is n
h re
hole
♦ Auxiliary measuring set -
spec
V.A.G 1594 A-
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
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rp
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o
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f
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ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

l wage 2004 ➤ , Golf Plus
ksGolf e2005
s no ➤ , Passat 2006 ➤ , Touran 2003 ➤
Vo t gu
by 4-cylinder diesel engine nte (1.9 l engine) - Edition 12.2013
d ara
rise
tho eo
au ra
3.2.1 Test procedure ss c
ce
le
un
pt
an
d
itte
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Note erm
ab
ility
ot p
wit
is n
Functional check and repair of optical and acoustic oil pressure
h re
warning: ⇒ Current flow diagrams, Electrical fault finding and Fit‐
ole,
spec
ting locations Guided fault finding with VAS 5051.
t to the co
– Remove oil pressure switch - F1- and screw into tester.
– Screw tester into oil filter bracket in place of oil pressure
rrectne
switch.
– Connect brown wire of tester to earth (-).
ss o
cial p
f
– Connect voltage tester - V.A.G 1527 B- to battery positive (+)
inform
and oil pressure switch using cable from auxiliary measuring
mer
set - V.A.G 1594 A- . LED must not light up.
atio
om
n
c
– Start engine and increase speed slowly.
i
or
n thi
te
sd
a
– At 0.55 ... 0.85 bar, the LED must light up; otherwise renew oil
iv
o
pr
c
pressure switch.
um
r
fo
en
ng
t.
– Increase engine speed further. At 2000 rpm and an oil tem‐
yi Co
op
perature of 80 °C the oil pressure should be at least 2.0 bar.
C py
t. rig
gh ht
yri by
At higher engine speeds, oil pressure must not exceed 7.0 bar. If
op Vo
by c lksw
cted
necessary renew oil filter bracket.
agen
Prote AG.
3.3 Assembly overview - oil supply line to turbocharger
1 - Retaining clamp
2 - 25 Nm
3 - Oil supply line
4 - 10 Nm
5 - Bracket
6 - Union nut, 22 Nm
7 - 10 Nm
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
3.4 Removing and installing oil supply line

en
ng
t.
yi Co
to turbocharger Cop py
t. rig
gh ht
yri by
op Vo
by c lksw
cted agen
Prote AG.
3.4.1 Removing
– Remove engine cover. ⇒ page 8
pipe.

of mounting.
– Loosen securing bolts for retaining clips.
– Loosen oil supply line union nuts on oil filter bracket and tur‐
bocharger. wage
e ks s no
Vol t gu
– Remove oil supply line.ed by ara
ris nte
utho eo
ra
a c
ss
ce
e
nl
pt
du
an
3.4.2 Installing
itte
y li
erm
ab
ility
ot p
wit
, is n
Note
h re
hole
spec
The procedure must be followed carefully to ensure that the oil
es, in part or in w
t to the co
supply line is installed tension-free.
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Loosen securing nut -2- from retainer -5-.
– Start union nuts for oil supply line on connections.

– Tighten union nut -8- on oil filter bracket hand tight.
– Tighten union nut -6- on turbocharger hand-tight.
– First tighten union nut -8- on oil filter bracket and then union
nut -6- on turbocharger to 22 Nm.
– Attach retaining clips -1- to brackets and tighten securing bolts
to 10 Nm.
– Tighten securing nut -2- to 25 Nm.
Further installation is basically the reverse of the removal proce‐
dure.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
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rp
cu
o
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ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

19 – Cooling
1 Parts of cooling system
WARNING

ment, pay attention to the following
n AG. Volksdue
wageto
n Athe
G docramped condi‐
tions: lkswage es n
Vo ot g
y ua
db r
♦ Route allhorthe
ise various lines (e.g. for fuel, hydraulics,anacti‐
tee
vated acharcoal
ut filter system, coolant and refrigerant, brake or
a
fluid and vacuum) and electrical wiring in their original po‐c
ss
ce
le
sitions.
un
pt
an
d
itte
y li
erm
ab
hot components.
ility
ot p
wit
is n
h re
ole,
spec
Note
t to the co
♦ When the engine is warm, the cooling system is under pres‐
sure. If necessary, release pressure before beginning repair
rrectne
work.
♦ Hoses are secured with spring-type clips. In case of repair, ss
only use spring-type clips.
o
cial p
f inform
♦ Spring-type clip pliers - VAS 5024- or hose clip pliers -

mer
V.A.G 1921- are recommended for fitting spring-type clips.

atio
om
n
c
♦ When installing coolant hoses, route stress-free so that they

i
or
n thi
do not come into contact with other components (observe

te
sd
a
markings on coolant connection and hose).

iv
o
pr
cum
r
fo
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
1. Parts of cooling system 121

Perform leakage test of cooling system using cooling system test‐

er - V.A.G 1274- and adapters adapter - V.A.G 1274/8- and
adapter - V.A.G 1274/9- .
⇒ “1.1 Coolant hoses”, page 122
⇒ “1.2 Draining and filling coolant”, page 125
AG. Volkswagen AG d
⇒ “1.3 Coolant pump, regulation of cooling system”, page
lksw
agen 129 oes
not
o
yV gu
⇒ “1.4 Parts of cooling system, body side (radiator
rised b
with two fans)”, ara
nte
page 133 ut
ho eo
ra
s a c
⇒ “1.5 Assembly overview - parts of cooling system, body side
s
ce
le
(radiator with one fan)”, page 135
un
pt
an
d
itte
y li
⇒ “1.6 Removing and installing fan support with fans (Golf, Golf
rm
ab
Plus, Touran)”, page 135
pe
ility
ot
wit
, is n
⇒ “1.7 Removing and installing fan support with fans (Passat)”,
h re
page 137
hole
spec
es, in part or in w
⇒ “1.8 Parts of cooling system - engine side ”, page 137
t to the co
⇒ “1.9 Removing and installing radiator (Golf, Golf Plus, Touran)”,
page 140
rrectness of i
⇒ “1.10 Removing and installing radiator (Passat)”, page 141
l purpos
⇒ “1.11 Checking engine oil cooler for leaks”, page 142
1.1 Coolant hoses
nform
mercia
a
⇒ “1.1.1 Coolant hose schematic diagram”, page 122
com
tion in
⇒ “1.1.2 Checking cooling system for leaks”, page 124
r
te o
thi
s
iva
do
⇒ “1.1.3 Checking pressure relief valve in filler cap”, page 125
r
rp
cum
fo
1.1.1 Coolant hose schematic diagram en

ng
t.
yi Co
Cop py
ht. rig
rig ht
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co Vo
by lksw
cted agen
Prote AG.
122 Rep. gr.19 - Cooling

1 - Expansion tank AG. Volkswagen AG d

agen oes
olksw not
yV gu
2- Rear coolant pipe ed b ara
nte
ris
ho eo
3- Bypass flapaut ra
c
ss
4 - Exhaust gas recirculation
ce
le
un
pt
cooler
an
d
itte
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rm
ab
5 - Cylinder head/cylinder
pe
ility
block
ot
wit
, is n
h re
6 - Heat exchanger for heater
hole
unit
spec
es, in part or in w
7 - Union
t to the co
8 - Front coolant pipe
rrectness of i
9 - Gearbox oil cooler
❑ if fitted
l purpos
❑ Only on vehicles with

automatic gearbox.
nform
ercia
10 - Upper coolant hose

m
a
com
tio
11 - Radiator
n in
r
te o
thi
12 - Lower coolant hose
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
14 - Coolant pump and ther‐ Cop py
mostat
t. rig
gh ht
pyri by
Vo
o
15 - Upper coolant pipe
by c lksw
cted agen
Prote AG.
16 - Circulation pump - V55-
❑ if fitted
17 - Auxiliary heater
❑ Vehicles with optional
equipment only.
Note
Coolant hose schematic diagram for vehicles with optional equip‐

ment ⇒ Heating, ventilation, air conditioning system; Rep. gr.
82 ; Connection diagram for coolant hoses in vehicles with auxil‐
iary heater

AG. Volkswagen AG d
agen oes
olksw not
yV gu
Golf 2004 ➤ , Golf Plus 2005 ed➤ , Passat 2006 ➤ , Touran 2003 ➤
b ara
nte
ris
4-cylinder diesel engine u(1.9
th l engine) - Edition 12.2013
o eo
ra
s a c
s
1.1.2 Checking cooling system for leaks
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
equipment required
wit
, is n
h re
hole
♦ Cooling system tester -
spec
V.A.G 1274-
es, in part or in w
t to the co
♦ Adapter for cooling system
tester - V.A.G 1274/8-
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Test prerequisite
• Engine at operating temperature.
Test sequence:
WARNING
Hot steam may escape when expansion tank is opened. Place

cloth over cap and open with caution.
– Open cap on coolant expansion tank.

– Attach cooling system tester - V.A.G 1274- with cooling sys‐

tem tester adapter - V.A.G 1274/8- to expansion tank.
– Use hand pump on tester to create a pressure of about 1.0 bar.
If pressure drops:
– Find leaks and rectify.
1.1.3 Checking pressure relief valve in filler

cap
tem tester adapter - V.A.G 1274/9- to cap.
– Use hand pump on cooling system tester to create a pressure
of max. 1.6 bar.
The pressure relief valve must not open.
If the pressure relief valve opens prematurely:
– Renew sealing cap.
– Increase pressure to over 1.6 bar.
The pressure relief wvalve
agen must open. AG doe
AG. Volkswagen
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If the pressure
ed
by relief valve does not open: ara
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– Renew
au
th sealing cap. eo
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1.2 Draining and filling coolant

un
pt
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es, in part or in w
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Prote AG.


equipment required
♦ Refractometer - T10007-
VAS 5024 A-
♦ Cooling system charge unit
- VAS 6096-
♦ Adapter - V.A.G 1274/8- n AG. Volkswagen AG do
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⇒ “1.2.1 Draining coolant”, page 126
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⇒ “1.2.2 Filling with coolant”, page 128
agen
Prote AG.
1.2.1 Draining coolant

WARNING
Hot steam may escape when expansion tank is opened. Place

cloth over cap and open with caution.

If drain plug is fitted:

wage es
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– To drain coolant not plug -arrow-.
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– Pull off lower coolant hose retaining clip -arrow- and remove
rrectne
coolant hose from quick-release coupling of radiator.
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– To drain coolant from engine, also remove coolant hose from
yri
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engine oil cooler -arrow-.
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Note
Observe environmental regulations for disposal.

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is tee
t or
4-cylinder diesel engine (1.9 l engine) - Edition
au 12.2013 ac
ss
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1.2.2 Filling with coolant
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Note
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♦ The amount of water used in the coolant mixture has a great
influence on its effectiveness. Because the water quality dif‐
t to the co
fers from country to country and even region to region, the
quality of the water to be used has been defined. Distilled wa‐
ter fulfils all requirements. For this reason, we recommend
rrectne
using distilled water when mixing coolant for topping up or re‐
placing coolant.
ss
♦ Use only coolant additives which conform with the ⇒ Elec‐
o
cial p
f
tronic parts catalogue (ETKA) . Other coolant additives may
inform
reduce corrosion protection substantially. The resulting dam‐
mer
age could lead to loss of coolant and subsequent severe
atio
m
damage to the engine.

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♦ The correct coolant solution ratio helps prevent damage due
te
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to freezing and corrosion as well as scaling. Moreover, the

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boiling temperature is raised. Therefore, the cooling system
um
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must be filled all year round with coolant additive.

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♦ Because of its higher boiling point, the coolant improves en‐
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tropical climates.
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♦ ONLY refractometer - T10007A- may be used for determining

current anti-freeze value.
♦ The normal frost protection must be for -25°C, in countries with
arctic conditions to -36°C. When climatic conditions require a
stronger frost protection, only then may the frost protection be
increased. But only to -48°C. Otherwise, the cooling effect of
the coolant will be impaired.
♦ The coolant concentration must not be reduced by adding wa‐
ter even in warmer seasons and in warmer countries. The frost
protection must be at least -25°C.
♦ Read off anti-freeze figures for respective replenished anti-
freeze.
♦ The temperature read off the refractometer - T10007A- equa‐
tes to the »ice flocculation point«. Flakes of ice can start
forming in the coolant below this temperature.
♦ Do not reuse old coolant.
♦ Use only a water/anti-freeze mixture as a slip agent for coolant
hoses.
Recommended mixing ratios (use only distilled water for mixing):

Frost protection Anti-freeze Coolant ad‐ Distilled wa‐
to proportion ditive 1) ter 1)
-25 °C 40 % 3.2 l 4.8 l
-36 °C 50 % 4.0 l 4.0 l
1)The quantity of coolant can vary depending upon the vehicle
equipment.
– Close coolant drain plug.
– Connect coolant hoses to engine oil cooler.
– Install noise insulation. ⇒ General body repairs, exterior; Rep.
gr. 50 ; Body - front; Assembly overview .
– Screw adapter - V.A.G 1274/8- onto expansion tank.

– Fill coolant circuit using cooling system charge unit -

VAS 6096-
Operating instructions for cooling system charge unit - VAS 6096-
are enclosed with unit.
Fill coolant expansion tank of -VAS 6096- with at least 8 litres of

pre-mixed coolant in correct mixture ratio.
Note
Exhaust air takes a slight quantity of coolant along with it; this
should be collected -2-. AG. Volkswagen A
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1.3 Coolant pump, regulation of cooling system t to the co

rrectness of i
l purpos
nform
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a
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tion in
r
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thi
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cum
fo
en
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t.
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Cop py
t. rig
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by
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Prote AG.


equipment required
♦ Torque wrench -
V.A.G 1331-
VAS 5024 A-
♦ Adapter - V.A.G 1274/8-
- VAS 6096-
AG. Volkswagen AG d
agen oes
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⇒ “1.3.1 Removing coolant pump”, page 130

⇒ “1.3.2 Installing coolant pump”, page 131
rrectness of i
⇒ “1.3.3 Coolant temperature regulation”, page 131

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1.3.1 Removing coolant pump

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Note
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Always renew seals and gaskets.

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– Remove toothed belt ⇒ page 70 .
gh ht
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– Remove securing bolts -1- for coolant pump -2- and carefully
remove coolant pump.
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1.3.2 Installing coolant pump
h re
hole
spec
es, in part or in w
t to the co
note the following:
– Moisten new O-ring -3- with coolant.
rrectness of i
– Insert coolant pump -2- in cylinder block and tighten securing
bolts -1- to 15 Nm.
l purpos
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ercia
Note
m
at
om
i
The coolant pump plug faces downwards.
on
c
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or
his
ate
– Install toothed belt ⇒ page 70 .
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or

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– Fill coolant system with coolant ⇒ page 125 . C py
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1.3.3 Coolant temperature regulation
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equipment required
♦ Torque wrench -
V.A.G 1331-
VAS 5024 A-
- VAS 6096-
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1.3.4 Removing thermostat
es, in part or in w
t to the co
Note
rrectness of i
Always renew seals and gaskets.
l purpos

nform
ercia
– Remove alternator. ⇒ Electrical system; Rep. gr. 27 ; Re‐

m
moving and installing alternator with poly V-belt .

com
tion in
– Pull coolant hose off connection.

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– Remove securing bolts -1- of connection -2- and remove con‐

nection -2- with thermostat -4-.
– Turn thermostat -4- 1/4 turn (90°) anticlockwise and remove it
from connection -2-.
AG. Volkswagen AG d
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1.3.5 Installingy thermostat
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Installation is carried
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note the following: au ra
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– Moisten new O-ring -3- with coolant.

nl
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– Insert thermostat -4- into connection -2- and turn 1/4 turn (90°) y li
erm
ab
clockwise.
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Note
spec
es, in part or in w
t to the co
The brace on the thermostat must be almost vertical.
– Insert connection -2- with thermostat -4- in cylinder block.

rrectness of i
– Tighten securing bolts -1- to 15 Nm.

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– Replenish coolant. ⇒ page 125

nform
mercia
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ate
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1.4 Parts of cooling system, body side (radiator with two fans)
t. rig
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❑ Coolant hose schematic
diagram ⇒ page 122 .
2 - O-ring
3 - Radiator
⇒ page 140
❑ After renewing, renew n AG. Volkswagen AG do
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entire coolant. byV
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4 - Cap tho tee
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❑ Check using cooling
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system tester -
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V.A.G 1274- and adapt‐
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❑ Test pressure 1.4 ... 1.6
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5 - Connector
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es, in part or in w
6 - 5 Nm
t to the co
7 - Expansion tank
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system tester -
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er - V.A.G 1274/8- .
8 - 5 Nm
nform
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9 - 10 Nm at
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10 - Fan support
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ate
11 - Additional fan
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❑ Vehicles with optional

for
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equipment only.
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12 - Radiator fan
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13 - Connector
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❑ Coolant hose schematic diagram ⇒ page 122 .
15 - Retaining clip
❑ Check for secure seating.
16 - Radiator outlet coolant temperature sender - G83-

1.5 Assembly overview - parts of cooling system, body side (radiator with one
fan)

2 - O-ring
3 - Radiator
⇒ page 140
AG. Volkswagen AG d
❑ After renewing, renew agen oes
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4 - Seal autho eo
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5 - Cap
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system tester -
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er - V.A.G 1274/9- .
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6 - Connector
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es, in part or in w
7 - 5 Nm
t to the co
8 - Expansion tank
rrectness of i
system tester -
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9 - Radiator mounting nf
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10 - 5 Nm
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atio
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11 - Mounting
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12 - Radiator fan
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13 - Fan support
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14 - 5 Nm t. Cop py
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15 - 5 Nm yri
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16 - Connector
agen
Prote AG.

18 - Retaining clip
19 - Radiator outlet coolant temperature sender - G83-
1.6 Removing and installing fan support

with fans (Golf, Golf Plus, Touran)

♦ Torque wrench (5... 50 Nm) - V.A.G 1331-
lkswage es n
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Removing
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The procedure for the single fan is identical.
, is n
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spec
es, in part or in w
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– Remove air intake duct from air filter.
rrectness of i
sition.
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– Separate connector -1- and remove fan support securing bolts

-arrows-.
nf
ercia
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– Remove fan support with fans upwards.
m
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– Separate connection -2- and free wiring.

– Unclip connector -1- from fan support and free wiring.
– Remove securing nuts -arrows- and remove fans.
Installing
note the following:
Specified torques: ⇒ Item 15 (page 135)
Component Nm
Radiator fan to fan support (single fan) 5
Radiator fan to fan support (double fan) 10
Fan mounting to radiator 5

1.7 Removing and installing fan support

with fans (Passat)
Removing
– Remove air intake duct from air filter.
G. Volkswagen
– Separate connector -1- andkswremove fan support securing
agen
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– Remove fan support
ut
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– Separate connection -2- and free wiring.

rrectness of i
– Unclip connector -1- from fan support and free wiring.

l purpos
– Remove securing nuts -arrows- and remove fans.

Installing
nform
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The procedure for the single fan is identical

m
at
om
io

n
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note the following:

o
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ate
do
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Specified torques: ⇒ Item 15 (page 135)

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Component Nm
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Radiator fan to fan support (single fan) 5
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Radiator fan to fan support (double fan) 10
Fan mounting to radiator 5
1.8 Parts of cooling system - engine side

1 - To top of expansion tank

2 - Upper coolant pipe
❑ Bolted to cylinder head
cover
3 - To bypass flap
4 - O-ring
❑ Renew
5 - Retaining clip
❑ Check for secure seat‐
ing. AG. Volkswagen AG d
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6 - Coolant temperature send‐ by V ol not
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❑ With coolant tempera‐ aut ra
c
ture display sender
s -
s
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7 - To exhaust gas recircula‐
erm
ab
tion cooler
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8 - Union
t to the co
9 - 10 Nm
10 - To heat exchanger
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11 - 40 Nm
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12 - Connecting piece
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13 - To bypass flap
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15 - To top of radiator
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❑ Coolant hose schematic diagram ⇒ page 122 . C py
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16 - 15 Nm copy Vo
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17 - To bottom of expansion tank
AG.

18 - Coolant pipe
19 - To bottom of radiator
20 - Union
❑ For thermostat
21 - Thermostat
❑ Observe installation position ⇒ page 129 , removing and installing thermostat.
❑ Checking: heat thermostat in water.
❑ Begins to open at approx. 85°C

❑ Ends at approx. 105°C
❑ Opening lift at least 7 mm.
AG . Volkswagen AG
22 - To heat exchanger ksw
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❑ Coolant hose schematic diagram
ed ⇒ page 122
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23 - Rear coolant pipe utho eo
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24 - 10 Nm
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25 - To auxiliary heater
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❑ Coolant hose schematic diagram ⇒ page 122
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26 - Coolant pipe
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27 - To exhaust gas recirculation cooler
spec
es, in part or in w
❑ Coolant hose schematic diagram ⇒ page 122
t to the co
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29 - Coolant pump
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❑ Check for ease of movement.

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1.9 Removing and installing radiator (Golf, Golf Plus, Touran)

equipment required
♦ Torque wrench -
V.A.G 1331-
VAS 5024 A-
- VAS 6096-
AG. Volkswagen AG d
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1.9.1 Removing (Golf, Golf Plus, Touran)

h re
hole
spec
– Bring lock carrier into service position. ⇒ General body re‐

es, in part or in w
pairs, exterior; Rep. gr. 50 ; Body - front; Lock carrier service

t to the co
position .
rrectness of i
– Pull coolant hoses off radiator.

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– Separate connector for radiator fan.

nf
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– Remove radiator securing bolts.

orm
m
– Remove radiator downwards.

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1.9.2 Installing (Golf, Golf Plus, Touran)

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note the following:

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– Fill with coolant. ⇒ page 125 C py
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1.10 Removing and installing radiator (Passat)
AG . Volkswagen AG
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equipment requiredby Vol gu
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♦ Refractometer
ut
ho - T10007-
r eo
ra
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♦ Torque wrench
s - V.A.G
ce
le
1331/-
un
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♦ Hose clip pliers - VAS
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ab
6340-
pe
ility
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rig ht
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Prote AG.
Removing
– Pull coolant hoses off radiator.
– Pull off connector for radiator fan.
– Remove cowling together with fans ⇒ page 137 .
– Remove bolts -arrow up- -arrow down- and lift radiator up and
out.
Installing
note the following:
– Replenish coolant ⇒ page 125 .

AG. Volkswagen AG d
agen oes
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Golf 2004 ➤aut, Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ra
c
➤
s
4-cylinder sdiesel engine (1.9 l engine) - Edition 12.2013
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1.11 Checking engine oil cooler for leaks
y li
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ility
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equipment required
spec
es, in part or in w
t to the co
♦ Hose clamps up to 25 mm -
3094-
rrectness of i
♦ Cooling system tester -
l purpos
V.A.G 1274-
nf
ercia
orm
m
atio
om
VAS 5024A-
n in
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♦ Drip tray - VAS 6208-

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Not illustrated:
♦ Expansion tank - 1K0 121 407 A- or -6Q0 121 407 A- or -1J0
121 407 B-
♦ Plug - 191 211 343-

♦ Cap - 1J0 121 324-

♦ Coolant hose - 251 265 056-
♦ Screw clamp
Test prerequisite:
• Engine cold
Test procedure
tion .
– Clamp supply line and return line off engine oil cooler using
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– Loosen spring-type by clips -arrows- using spring-type uclip
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Collect escaping coolant with drip tray - VAS 6208- .
ility
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is n
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– Pull coolant hoses off engine oil cooler.
ole,
spec
t to the co
– Push sealing cap -5- to rear connection of engine oil cooler
-4-.
rrectne
– Secure sealing plug -2- to breather connection of expansion
tank -1-.
ss
– Secure coolant hose -3- to oil cooler and expansion tank.

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f in
– Fill expansion tank up to “Max” marking.

form
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atio

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tem tester adapter - V.A.G 1274/8- to expansion tank.

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Use hand pump on tester to create a pressure of about 1.6 bar.

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Watch pressure drop on pressure gauge. A pressure drop within

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10 minutes is not permitted.

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– Renew engine oil cooler. by c lksw
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Assembly is carried out in the reverse order, note the following:
– Check coolant level, if necessary replenish coolant.

20 – Fuel supply system

1 Safety precautions
⇒ “1.1 Safety precautions when working on fuel supply system”,
page 144

fuel supply system
WARNING

tions:
sitions.
hot components.
carefully loosen connection to release theagpressure!
en AG. V
olkswagen AG
do w es n
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♦ Wear eye and hand protection when by performing any type
V ua
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When removing and installing fuel gauge sender or fuel pump

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(fuel delivery unit) from a full or partly full fuel tank, observe the
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following:
erm
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♦ Even before work commences, the extraction hose of an ac‐

wit
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tivated fume extraction system has to be placed in the vicinity

h re
hole
of the assembly opening of the fuel tank to extract any escap‐

spec
ing fumes. If no exhaust extraction system is available, a radial

es, in part or in w
t to the co
fan with a displacement greater than 15 m3/h can be used

providing that motor is not in air flow.
♦ Prevent skin contact with fuel! Wear fuel-resistant gloves!
rrectness of i
l purpos
nform
mercia
at
om
ion
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or
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ate
do
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144 Rep. gr.20 - Fuel supply system

2 Rules for cleanliness

⇒ “2.1 Rules for cleanliness when working on fuel supply system”,
page 145
2.1 Rules for cleanliness when working on

fuel supply system
When working on the fuel supply and injection system, observe
the following “6 rules” for cleanliness:
♦ Thoroughly clean all unions and surrounding areas before dis‐
connecting.
lint-free cloths.
♦ Carefully cover opened components or seal if repairs cannot
be carried out immediately.
tool boxes etc.).
♦ When system is open: do not work with compressed air if this
can be avoided. Do not move vehicle unless absolutely nec‐
essary.
AG. Volkswagen AG d
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es, in part or in w
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tion in
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Cop py
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145
c by lksw
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Prote AG. 2. Rules for cleanliness
3 Parts of fuel supply system (Golf, Golf

Plus)
⇒ “1 Safety precautions”, page 144
⇒ “3.1 Fuel tank, vehicles with front-wheel drive ”, page 146
⇒ “3.2 Fuel tank, vehicles with four-wheel drive ”, page 149
⇒ “3.3 Emptying fuel tank”, page 156 olkswage es n
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byV ua
⇒ “3.4 Removing and installing fuel delivery
ir se unit ”, page 158
d ran
tee
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⇒ “3.5 Removing and installing fuelssgauge
au sender”, page 159 ac
ce
e
⇒ “3.6 Checking fuel pump”, page 160

nl
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itte
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⇒ “3.7 Assembly overview - fuel filter”, page 164
erm
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⇒ “3.8 Removing and installing fuel cooler”, page 166
wit
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3.1 Fuel tank, vehicles with front-wheel
hole
spec
drive
es, in part or in w
t to the co
Note
rrectness of i
♦ Hose connections are secured with either spring-type or
l purpos
clamp-type clips.
♦ Always renew crimp-type clips with spring-type clips.
nform
ercia
♦ Spring-type clip pliers - VAS 5024/- or hose clip pliers - V.A.G

m
at
om
i
1921/- are recommended for installation of spring-type clips.
on
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ate
3.1.1 Assembly overview - fuel tank do

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for
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Prote AG.

1 - Cap
2 - 1.5 Nm
3 - Earth connection
4 - 10 Nm
5 - Cable guide
6 - Fuel tank
❑ When removing, sup‐
port using engine and
gearbox jack - V.A.G
1383/A- .
⇒ page 148
7 - 25 Nm
❑ Renew
8 - Clamping washer
9 - Securing strap
❑ Note installation posi‐
tion
10 - Heat shield
❑ For fuel tank
11 - Seal
❑ Renew if damaged agen
AG. Volkswagen AG d
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12 - Fuel delivery unitss a c
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❑ With fuel gauge sender

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ab
ility
tion of flange on fuel

ot p
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tank ⇒ page 170

, is n
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hole
spec
❑ Checking fuel pump ⇒ page 160

es, in part or in w
t to the co
❑ Removing and installing fuel gauge sender ⇒ page 178

13 - Locking ring
rrectness of i
❑ Remove and install using wrench - T10202-

l purpos
❑ Specified torque: 110 Nm

14 - Supply line
nf
ercia
❑ To fuel filter
rm
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❑ Clipped onto fuel tank

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❑ Black
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❑ To pull off flange, press release button on connecting piece

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15 - Return line
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❑ From fuel cooler
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3. Parts of fuel supply system (Golf, Golf Plus) 147

16 - Tank flap unit

❑ Removing and installing ⇒ General body repairs, exterior; Rep. gr. 55 ; Tank flap unit
3.1.2 Removing and installing fuel tank

♦ Torque wrench - V.A.G 1331/-
♦ Engine and gearbox jack - V.A.G 1383/A-
lkswage es n
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Removing
un
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– Note safety precautions before beginning work ⇒ page 144 .
rm
ab
pe
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Observe rules for cleanliness ⇒ page 145 .

ot
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spec
Note
es, in part or in w
t to the co

rrectness of i
♦ When lowering fuel tank, guide it carefully to prevent damage.

l purpos
– Disconnect earth strap from battery with ignition switched off

nform
ercia
⇒ Electrical system; Rep. gr. 27 ; Battery; Disconnecting and

reconnecting battery .
m
a
com
tion in
– Remove rear bench seat (Golf Plus: rear right seat) ⇒ General
r
te o
thi
body repairs, interior; Rep. gr. 72 ; Rear seats; Removing and

s
iva
installing bench seat .

do
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by
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Prote AG.

– Remove cover from fuel delivery unit.

– Pull connector off flange.
– Remove fuel flap unit. ⇒ General body repairs, exterior; Rep.
gr. 55 ; Fuel flap unit
– Emptying fuel tank ⇒ page 156 .
– Remove rear right wheel housing liner: ⇒ General body re‐
pairs, exterior; Rep. gr. 66 ; Removing and installing wheel
housing liner .
– Remove bolts from filler neck -arrows-.
AG. Volkswagen AG d
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– Disconnect fuel lines at front right of fuel tank.
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spec
Note
t to the co
Press buttons on hose couplings to do this.
– If vehicle has supplementary heating, separate connector to rrectne

metering pump and unclip wire. ⇒ Supplementary heating;
Rep. gr. 82 ; Removing and installing metering pump -V54
ss o
cial p
– Remove bolts -A- and remove heat shield for fuel tank.
inform
mer
– Support fuel tank using engine and gearbox jack - V.A.G 1383/
atio
A- .
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– Remove securing bolts -arrows- for the fuel tank.

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– Slowly lower fuel tank and pull it forwards.

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– Tilt fuel tank to get it past rear axle.
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Installing
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Install in reverse order. In the process, note the following: cted agen
Prote AG.
♦ Install breather and fuel hoses free of kinks.

♦ Clip supply and return lines onto fuel tank.
3.2 Fuel tank, vehicles with four-wheel drive
3.2.1 Assembly overview - fuel tank

1 - Supply line
❑ Black
2 - Return line
❑ Blue
3 - Seal
❑ Renew
❑ When installing, fit dry in
fuel tank opening
❑ Moisten with fuel only
when installing flange
4 - Fuel delivery unit
⇒ page 158 n AG. Volkswagen AG do
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❑ Checking fuel pump yV
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❑ Note installation posi‐ o
ir se tee
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ac
⇒ page 151 ss
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❑ With fuel gauge sender
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an
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- G- .
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fuel gauge sender
wit
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⇒ page 178
h re
ole,
spec
5 - Locking ring, 110 Nm
t to the co
❑ Remove and install us‐
ing wrench - T10202-
rrectne
6 - Tank flap unit
❑ With rubber cup
ss o
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⇒ General body repairs, exterior; Rep. gr. 55 ; Tank flap unit; Removing and installing fuel tank flap unit
form
mer
atio
7 - Cap
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8 - Securing bolt
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❑ Tighten to 1.5 Nm.

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9 - Earth connection t. Cop py
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10 - 10 Nm
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11 - Suction-jet pump
❑ Clipped onto fuel gauge sender 2 - G169-
12 - Fuel gauge sender 2 - G169-
13 - Fuel tank
❑ When removing, support using engine and gearbox jack - V.A.G 1383 A- .
14 - Securing strap
15 - 25 Nm
❑ Renew

16 - Heat shield
❑ Riveted to exhaust pipe mounting
Installation position of flange for fuel delivery unit and fuel gauge
sender 2 - G169-
The marking on the flange must align with the marking on the fuel
tank -arrow-. en AG. V
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The marking on the fuel tank is not clearly visible.
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♦ Engine and gearbox jack - V.A.G 1383 A- ht. rig
rig ht
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Prote AG.
Note
Before disconnecting battery, open fuel tank flap and if necessary

remove wheel lock adapter from luggage compartment.
– First check whether a coded radio is fitted. If so, obtain anti-

theft coding.

If necessary, drain fuel tank using fuel extractor - VAS 5190- .

⇒ page 156
– Remove rear right wheel.
– Remove rear right wheel housing liner. ⇒ General body re‐
pairs, exterior; Rep. gr. 66 ; Removing and .installing
Volkswagenwheel
gen AG
housing liner; Rear wheel housing kliner
swa .
AG do
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– Unscrew securing bolts andiseremove
db tank flap unit. ⇒ General ran
body repairs, exterior; Rep.
ut
hor
gr. 55 ; Fuel flap unit tee
or
sa ac
– Unscrew filler neck from
s body -arrows- and unclip electrical
ce
le
wire from filler neck.

un
pt
an
d
itte
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– Remove bench seat ⇒ General body repairs, interior; Rep. gr.
rm
ab
72 ; Rear seat; Removing and installing bench seat .
pe
ility
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wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
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– Remove covers and separate electrical connectors -arrows-.
nform
ercia
– Remove centre and rear silencers.

m
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tion in
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Prote AG.
– Secure exhaust system to underbody using wire.

– Remove rear propshaft ⇒ Manual gearbox; Rep. gr. 39 ; Final
drive, differential, differential lock
WARNING
Fuel supply line is pressurised. Wear eye protection and pro‐

tective clothing to avoid possible injury and skin contact. Before
loosening hose connections, wrap a cloth around the connec‐
tion. Then release pressure by carefully pulling hose off con‐
nection.

– Pull off adapter cable on four-wheel drive control unit - J492- .
– Support fuel tank using engine and gearbox jack - V.A.G 1383
A- and unscrew tensioning straps and securing bolts.
– Slowly lower fuel tank.
Note
The filler neck must be “guided out” between body and rear axle.
To do this, take the fuel tank off engine and gearbox jack - V.A.G
1383 A- with the assistance of a 2nd mechanic.
– Clip in cable for four-wheel drive control unit - J492- on fuel

tank.
– With the aid of a 2nd mechanic, guide thewfiller
gen Aneck
G. Voin
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wagen AG
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rear axle and body. Then place the yfuel
Volktank on the engine and s not gu
gearbox jack - V.A.G 1383 A- .ised b ara
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– Raise fuel tank slowly up to installation position and secure it

es, in part or in w
in place.
t to the co
rrectness of i
l purpos
nform
mercia
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tion in
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te o
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Cop py
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Prote AG.

– Fit adapter cable on four-wheel drive control unit - J492- .

The remaining installation steps are carried out in the reverse se‐
quence. In the process, note the following:
♦ Install breather and fuel lines free of kinks.
♦ Ensure that line connections are tight.
♦ Check earth connection on fuel tank and body to filler neck.
3.2.3 Removing and installing fuel gauge

sender 2 - G169-
• The fuel tank should be no more than half full
Note
AG. Volkswagen AG d
♦ Ensure that the fuel gauge sender is notolbent.
ksw
agen oes
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♦ If necessary, drain fuel tank usingrisfuel
ed extractor - VAS 5190- . ara
nte
⇒ page 156 ut
ho eo
ra
a c
ss
♦ Note safety precautions before beginning work ⇒ page 144 .
ce
e
nl
pt
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♦ Observe rules for cleanliness ⇒ page 145 .
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itte
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ility
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Removing:
wit
, is n
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hole
theft coding.
spec
es, in part or in w

t to the co
rrectness of i

l purpos
– Remove left cover (as seen facing direction of normal travel)

from fuel gauge sender 2 - G169- .
nform
ercia
– Disconnect electrical connectors.

m
at
om
ion
– Open locking ring using wrench - T10202- .

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or
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ate
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en
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t.
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t. rig
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pyri by
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Prote AG.

– Pull fuel gauge sender 2 - G 169- upwards slightly and unclip

it from the suction-jet pump.
Installing:
Caution
When installing do not bend fuel gauge sender 2 - G169- float

arm.
– Place fuel gauge sender 2 - G 169- in fuel tank.
– Fit suction-jet pump on sender on inside of fuel tank. Locating

lugs must engage.
– Place a new flange seal dry into aperture in fuel tank and
moisten only inside (contact to flange) with fuel.
– Note installation position of fuel gauge sender 2 - G169-
⇒ page 151
– Check correct position of seal.
AG. Volkswagen AG d
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V
– Tighten locking ring using wrench - T10202- . Specified
ed by torque: gu
ara
110 Nm horis nte
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– Fit connectors. ss c
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nl
pt
– Install cover.
du
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itte
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erm
– Install bench seat. ⇒ General body repairs, interior; Rep. gr.
ab
ility
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wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
3.2.4 Removing and installing suction-jet
pump (Golf, Golf Plus)
l purpos
nform
ercia
Note
m
at
om
io
♦ On vehicles with all-wheel drive, a suction-jet pump must

n
c
in t
or
pump the fuel from the area of fuel gauge sender 2 - G169- to
his
ate
the fuel pump due to the shape of the fuel tank.

do
priv
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or
♦ Checking is only necessary when the engine stops due to lack

f
en
ng
t.
of fuel, even though the fuel gauge shows that the tank is still
yi Co
op
1/4 full.
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t. rig
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Procedure cted agen
Prote AG.
– Remove fuel delivery unit ⇒ page 158 .

– Pull return hose of suction-jet pump out of fuel delivery unit

-arrow-.
– Separate plug-in connector of supply line from suction-jet
pump on Y-piece of fuel delivery unit.
– Remove fuel gauge sender 2 - G 169- ⇒ page 154 .
– Now the suction-jet pump can be pulled out from the side of
the fuel gauge sender 2 - G169- (left side of vehicle).
– Check that the fuel lines on suction-jet pump are fitted securely
and are not damaged.
– Additionally check suction-jet pump for possible soiling.
3.3 Emptying fuel tank

♦ Fuel extractor - VAS 5190- AG. Volkswagen AG d
agen oes
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t to the co
♦ Fuel tank sender unit tool - T10202-
rrectness o
cial p
f inform
mer
atio
om
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c
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or
n thi
te
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Cop py
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♦ Torque wrench (40... 200 Nm) - V.A.G 1332- rig ht
py by
co Vo
by lksw
– Note safety precautions before beginning work ⇒ page 144 . Prote
cted AG.
agen
Emptying fuel tank if it is more than 3/4 full ⇒ page 156 .
Emptying fuel tank if it is less than 3/4 full ⇒ page 157
3.3.1 Emptying fuel tank if it is more than 3/4

full
Caution
Secure earth wire of fuel extractor - VAS 5190- to a bare metal

part of the body.

– Remove cotter -2- from shaft -1- of fuel extractor - VAS 5190- .
– At distance -a- = 1180 mm from end, mark extraction hose with
insulating tape -arrow-.
AG. Volkswagen AG d
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– Remove filler cap from fuel tank filler neck.
ility
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– Screw shaft end -1- of fuel extractor unit - VAS 5190- onto fuel
h re
hole
filler neck.
spec
es, in part or in w
– Push extraction hose into fuel tank until marking on hose
t to the co
-arrow- coincides with shaft end.
rrectness of i
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ercia
orm
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Note
thi
te
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A ball valve -2- is located at the bottom of the filler neck in the fuel
o
m
f
en
ng
tank -1-; it must not be damaged by the extraction hose -3-.

t.
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Therefore push hose into filler neck only as far as marking Cop py
t. rig
-arrow-. opyri
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ht
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– Empty fuel tank as far as possible. Prote AG.
– Carefully pull out extraction hose.
Note
♦ When no more fuel is extracted, the tank is emptied just

enough for the sender flange to be opened without danger.
♦ If the fuel tank has to be drained fully, proceed as follows:
⇒ page 157
3.3.2 Emptying fuel tank if it is less than 3/4 full

72 ; Rear seats; Removing and installing bench seat .
WARNING

nection.

– Pull connector and fuel lines off flange.
Note
– Open locking ring using fuel tank sender wrench - T10202- .

– Lift sender flange.
– Insert extraction hose of fuel extractor - VAS 5190- as deeply
as possible into fuel tank and extract fuel.
If fuel tank needed only to be emptied, reinstall sender flange.
3.4 Removing and installing fuel delivery

unit
Special tools and workshop equipment
gen AG required n AG d
. Volkswage
a oes
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♦ Wrench - T10202- Vol gu
d by ara
e nte
ris
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nl
pt
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itte
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ab
ility
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, is n
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es, in part or in w
t to the co
rrectness of i

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nf
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orm
m
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n in
or c
thi
te
sd
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Cop py
t. rig
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Removing cted agen
Prote AG.
Observe safety precautions ⇒ page 144 .

theft coding.

– Remove rear bench seat (Golf Plus: rear right seat) ⇒ General
body repairs, interior; Rep. gr. 72 ; Rear seats; Removing and
installing bench seat .
– Pull 5-pin connector and fuel lines off flange.
Note
WARNING
– Remove union nut with wrench - T10202- .

– Pull fuel delivery unit and seal out of the opening in fuel tank.
Note
If delivery unit is to be renewed, drain old delivery unit before dis‐

posal.
wage es n
Installing yV
olks ot g
ua
b
ed ran
– Installing the fuel delivery unit is carried out in reverse
thoris
order tee
or
of removal. au ac
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Note
erm
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ility
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wit
♦ Do not bend fuel gauge sender when installing.

is n
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ole,
♦ Insert seal for flange or fuel delivery unit dry into opening of
spec
fuel tank.
t to the co
♦ Moisten seal with fuel only when installing flange or fuel de‐
livery unit.
rrectne

♦ After installing fuel delivery unit, check that the supply, return
ss
and breather lines are still clipped onto the fuel tank.
o
cial p
f inform
♦ Note installation position of fuel delivery unit flange: mark on

mer
flange must align with mark on fuel tank -arrows-.

atio
om
n
c
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or
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3.5 Removing and installing fuel gauge

t
sd
iva
o
pr
sender
um
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fo
en
ng
t.
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Removing t. Cop py
rig
gh ht
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– Remove fuel delivery unit ⇒ page 158 . p by
co Vo
by lksw
cted agen
Prote AG.

4-cylinder diesel engine (1.9 l engine) - Edition 12.2013AG. Volkswagen A
n G do
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– Release connector lugs on lines -3- and -4- andedpullby off. ua
ran
oris tee
– Lift retaining tabs -1- and -2- using a screwdriver
au
th and pull off or
ac
fuel gauge sender downwards -arrows-. ss
ce
e
nl
pt
Installing
du
an
itte
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– Insert fuel sender into guides on fuel delivery unit and press
erm
ab
ility
upwards until it engages.
ot p
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
3.6 Checking fuel pump
l purpos
Note
nf
ercia
orm
Check fuel filter connections for correct arrangement, before
m
atio
m
starting to check the fuel pump ⇒ page 164

o
n in
or c
thi
te
sd
3.6.1 Checking delivery pressure of fuel pump
iva
o
r
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cu
o
m
f
en
ng
t.
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op py
♦ Pressure tester - VAS 6550- . C rig
ht ht
rig by
py
♦ Vehicle diagnostic tester
co Vo
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cted agen
Prote AG.
Test prerequisite:
• Fuses must be OK.
• Battery voltage at least 12 V
• All electrical consumers, e.g. lights and rear window heating,
must be switched off.
– Separate plug-in connector -A- (completely black or with black
marking) of fuel supply line.
– Connect pressure tester - VAS 6550- with cables -VAS
6550/1- and -VAS 6550/2- to open ends of fuel supply line.
– Switch on pressure tester - VAS 6550- by pressing On/Off
button.
– Open shut-off taps “A” and “B” of pressure tester and close
shut-off tap “C”.
– Start engine and run at idling speed.
– Read pressure on pressure tester - VAS 6550- . Specification:
min. 0.5 bar.
– Place pressure tester - VAS 6550- onto windscreen so that it
can be read from inside vehicle.
– Increase idling speed to 2500 rpm and read the pressure on
pressure tester - VAS 6550- , specification min 0.25 bar.
– If the delivery pressure temporarily drops, renew fuel delivery
unit ⇒ page 188 .
– If the specifications are attained, check tandem pump to en‐
sure the fuel filter is not blocked ⇒ page 204 .
– If the tandem pump values are OK, check fuel pump delivery
rate ⇒ page 161 .

3.6.2 Checking fuel pump delivery rate

♦ Pressure gauge - VAS 6550-
♦ Container > 3 litre with measuring scale
Test prerequisite: lkswage es n
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byV ua
• Fuses must be OK. ir se
d ran
tee
tho
u or
• Battery voltage at least 12 V ss
a ac
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nl
pt
du
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itte
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erm
ab
ility
ot p
wit
Note
, is n
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hole
spec
The delivered fuel may be cloudy. This is normal and can be ig‐
es, in part or in w
nored.
t to the co
rrectness of i
– Connect -VAS 6550/1- pressure tester line to fuel supply -A-.
l purpos
– Guide open end of line into measuring container.
nf
ercia
o
– Connect vehicle diagnostic tester and perform guided function
rm
m
“checking electric fuel pump(s)”.
atio
om
n in
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thi
e
Note
t
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The fuel pump is now actuated for 30 seconds.
en
ng
t.
yi Co
Cop py
t. rig
– After fuel flow ceases, read quantity of fuel delivered on meas‐
gh ht
yri by
uring container, specification: min. 1000 ml/30 s.
cop Vo
by lksw
cted agen
Prote AG.
If the specification is not attained:
– Check fuel supply line between fuel pump and engine com‐
partment for kinks, crushes or damage.
– If necessary, renew defective line and repeat test.
– If it is not kinked, crushed or damaged, remove rear seat bench
⇒ General body repairs, interior; Rep. gr. 72 ; Rear seats .
– Detach carpet under seats and fold it back. ⇒ General body
repairs, interior; Rep. gr. 70 ; Load and luggage compartment
trim; Removing and installing luggage compartment floor
Note
Press in securing ring to release fuel line.

– Pull fuel supply line (black or black marking) -A- off fuel deliv‐
ery unit.
– Connect diagnostic tester and perform the guided function
“Checking electric fuel pump(s)”.
Note
– After fuel flow, read quantity of fuel delivered on measuring

container, specification: min. 1000 ml/30 s.
– Check voltage supply ⇒ page 162 and current draw
⇒ page 163 of fuel pump.
3.6.3 Checking voltage supply of fuel pump

♦ Hand-held multimeter - V.A.G 1526D-
♦ Pickup clamp - V.A.G 1526B/2-
♦ Test instrument adapter/DSO (5-pin) - VAS 5565-
lkswage es n
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ir se tee
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ss
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Test prerequisites
h re
hole
spec

es, in part or in w
t to the co
• The battery voltage must be at least 12 V, if necessary connect

a battery charger.
rrectness of i

l purpos
– Remove seat bench ⇒ General body repairs, interior; Rep. gr.

72 ; Rear seats .
nform
ercia

m

a
com
tio

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r
te o
thi

s
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– Switch on ignition. The fuel pump must be heard to run for

um
fo
en
about 2 seconds.
ng
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– Switch off ignition. t. C rig
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pyri by
Vo
If the fuel pump does not start:
co lksw
by
cted agen
Prote AG.
– Pull connector off fuel delivery unit flange.

– Connect test instrument adapter/DSO (5-pin) - VAS 5565- be‐

tween connector and flange.
– Connect hand-held multimeter - V.A.G 1526D- to contacts
-1- and -5- of adapter.
Note
The fuel pump is now actuated for 30 seconds. n AG. Volkswagen AG do

lkswage es n
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– Read voltage value on hand-held multimeter
ir se
d - V.A.G 1526D- : ran
tee
Specification = battery voltage. utho
or
a ac
ss
If no voltage is present:
ce
le
un
pt
an
– Check activation of fuel pump relay and wiring for an open or
d
itte
y li
short circuit ⇒ Vehicle diagnostic tester.
erm
ab
ility
ot p
Voltage supply OK:
wit
is n
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ole,
spec
– Check that electrical wiring between flange and fuel pump is
t to the co
connected and has continuity.
If no open circuit can be found:
rrectne
– Renew fuel delivery unit.
ss
3.6.4 Checking current draw of fuel pump
o
cial p
f inform
mer
atio
m
♦ Hand-held multimeter - V.A.G 1526D- or pickup clamp - V.A.G

o
n
c
1526B/2-
i
or
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te
sd
a

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pr
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fo

en
ng
t.
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Cop py
t. rig
gh ht
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Note p by
co Vo
by lksw
cted agen
Prote AG.
The battery voltage and the diesel fuel temperature have a great
influence on the current draw of the fuel pump. For this reason
ensure that the battery voltage is at least 12 V whilst checking and
the diesel fuel temperature does not fall to the freezing point.
Test prerequisites
• Diesel fuel temperature above (10 ) C
72 ; Rear seats .

– Pull connector -C- off flange.
– Connect test instrument adapter/DSO (5-pin) - VAS 5565- to

connector and fuel delivery unit.
– Connect pick-up clamp -A- to red terminal with lettering “pick-
up clamp” for test instrument adapter/DSO (5-pin) - VAS
5565- .
Note
Pickup clamp of hand-held multimeter - V.A.G 1715- can also be

connected to red terminal with lettering “pickup clamp” of test in‐
strument adapter/DSO (5-pin) - VAS 5565- .
AG. Volkswagen AG d
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– Switch on ignition. ed by gu
ara
ris nte
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– Connect vehicle diagnostic tester and perform guided
aut
h function eo
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“checking electric fuel pump(s)”. ss c
ce
le
un
pt
an
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itte
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Note
rm
ab
pe
ility
ot
wit
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hole
spec
– Read current draw on hand-held multimeter - V.A.G 1526D- .
es, in part or in w
Specification: max. 7.5 amps.
t to the co
– If the measured value is not within specifications:
– Renew fuel delivery unit ⇒ page 188 . rrectness of i
l purpos
3.7 Assembly overview - fuel filter

nform
mercia
Note
a
com
tion in
r
Note that there are different versions of fuel filter upper part
te o
thi
⇒ page 166 .
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1 - Supply line
❑ From fuel tank
❑ White or with white
marking
2 - 5 Nm
3 - Return line
❑ To fuel cooler
❑ Blue or with blue mark‐
ing
4 - Plug for water extraction
❑ Remove and extract
about 100 cm3 liquid us‐
ing hand-operated vac‐
uum pump with acces‐
sories - V.A.G 1390-
and water drainage con‐AG. Volkswagen AG d
tainer - V.A.G 1390/1-
lksw
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5 - Seal ris
ed
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❑ Renew
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6 - Supply line
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❑ To tandem pump
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7 - Return line
ility
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❑ From tandem pump

wit
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spec
ing
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8 - Upper part of fuel filter
rrectne
9 - Fuel temperature sender -

G81-
ss
10 - Seal
o
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❑ Renew
form
mer
11 - Filter insert
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12 - Seal
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❑ Renew
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13 - Lower part of fuel filter

fo
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14 - 8 Nm Cop py
t. rig
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15 - Bracket p by
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16 - Seal Prote AG.
❑ Renew
17 - Retaining clip
18 - Union
19 - From tandem pump

3.7.1 Upper part of fuel filter yV
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Type A ⇒ page 166 ir se tee
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Type B ⇒ page 166 ss
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Fuel filter upper part, type A
pt
an
d
itte
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1 - 8 Nm
erm
ab
ility
ot p
2 - Plug for water extraction (remove and extract about 100 cm3
wit
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liquid using hand-operated vacuum pump with accessories -
h re
ole,
V.A.G 1390- and water drainage container - V.A.G 1390/1- ,
spec
renew seal)
t to the co
3 - Fuel supply line from fuel tank, white or white marking. Check
for secure seating.
rrectne
4 - Fuel return line to fuel tank, blue or blue marking. Check for
secure seating.
ss
5 - Fuel supply line to engine, white or white marking. Check for
o
cial p
f
secure seating.
inform
mer
6 - Fuel return line from engine, blue or blue marking. Check for
atio
m
secure seating.
o
n
c
i
or
n thi
te
Upper part of fuel filter, type B
sd
iva
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pr
cum
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1 - 5 Nm
fo
en
ng
t.
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2 - Fuel return line to fuel tank, blue or blue marking. Check for Cop py
secure seating.
t. rig
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Prote
for secure seating.
AG.
secure seating.
secure seating.
3.8 Removing and installing fuel cooler

Removing

AG. Volkswagen AG d
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Golf 2004Vol ➤ , Golf Plus 2005 ➤ , Passat
ksw es n
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by ua
rised 4-cylinder diesel engine (1.9 lraengine)
nt - Edition 12.2013
ee
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s
ce
le
Note
un
pt
an
d
itte
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rm
The fuel cooler is located in the return line to fuel tank. It is located
ab
pe
ility
on the vehicle underbody.
ot
wit
, is n
h re
hole
– Remove underbody panel.
spec
es, in part or in w
– Separate fuel lines at fuel cooler.
t to the co
– Remove securing nuts -arrows-.
Installing
rrectness of i
l purpos
♦ Tighten fuel cooler securing nuts to 15 Nm.
nform
mercia
a
com
tion in
r
te o
thi
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t. rig
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4 Parts of fuel supply system (Touran)
Note
♦ Hose connections are secured with either spring-type or

clamp-type clips.
♦ Always renew crimp-type clips with spring-type clips.
♦ Spring-type clip pliers - VAS 5024/- or hose clip pliers - V.A.G
1921/- are recommended for installation of spring-type clips.

page 145
⇒ “4.1 Assembly overview - fuel tank with attachments”,
page 168
⇒ “4.2 Emptying fuel tank”, page 170
⇒ “4.3 Removing and installing fuel tank”, page 173
⇒ “4.6 Removing and installing fuel delivery unit”, page 176
⇒ “4.7 Removing and installing fuel gauge sender”, page 178
wage
4.1 Assembly overview - fuel tank with attachments byV
olks es n
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nl
pt
du
an
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erm
ab
ility
ot p
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, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
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for
en
ng
t.
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Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.

1 - Cap
2 - 1.5 Nm
3 - Tank flap unit
❑ Removing and instal‐
ling. ⇒ General body re‐
pairs, exterior; Rep. gr.
55 ; Fuel flap unit
5 - 10 Nm
6 - Pressure retention valve
with connecting hose
7 - Gravity/overflow valve
8 - Fuel tank
gearbox jack - V.A.G
1383/A- .
⇒ page 173 .
9 - Heat shield
❑ For fuel tank
10 - Securing strap
11 - 20 Nm + turn (90°)
❑ Renew
Note
To secure the securing straps for gen AG

. Volkswagen AG
the fuel tank, only bolts with looseVolkswa does
not
washers must be used. If different d by gu
ara
bolts are used, the securing rise
straps nte
ho eo
might twist during tightening.
sa
ut ra
c s
ce
e
nl

pt
du
an
itte
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❑ With fuel gauge sender (G).

erm
ab
ility
❑ Note installation position of flange on fuel tank ⇒ page 170 .

ot p
wit
, is n

h re
hole
❑ Checking fuel pump ⇒ page 160 .

spec
es, in part or in w
❑ Removing and installing fuel sender ⇒ page 178 .

t to the co
❑ Clean strainer if soiled.

13 - Seal
rrectness of i
❑ Renew
l purpos
❑ Moisten with fuel when installing.

nform
ercia
❑ Remove and install using union nut tool - 3217- .

m
at
om
io
15 - Supply line
n
c
in t
or
❑ To fuel filter
his
ate
do
riv

p
cum
or

f
en
ng
t.
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❑ Black Cop py
t. rig
gh
ht
pyri by
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co lksw
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cted agen
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169
AG.
4. Parts of fuel supply system (Touran)
16 - Return line
Installation position of fuel delivery unit

Marking on flange must align with marking on fuel tank -arrows-.
Black supply line -1- to connection marked -V-.
Return line -2- (blue or with blue marking) to connection marked
-R-.
AG. Volkswagen AG d
agen oes
lksw not
Note by Vo gu
ara
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rise nte
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After installing fuel delivery unita flange, check that supply, return
th
u ra
and breather lines are still clipped onto fuel tank.
ss c
ce
le
un
pt
an
d
itte
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4.2 Emptying fuel tank
rm
ab
pe
ility
ot
wit
, is n
h re
hole
♦ Fuel extractor - VAS 5190-
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
♦ Union nut tool - 3217-

rp
cum
fo
en
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Cop py
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Emptying fuel tank if it is more than 3/4 full ⇒ page 171 .
Emptying fuel tank if it is less than 3/4 full ⇒ page 172

full
Caution
. Volkswagen AG
Secure earth wire of fuel extractor - VAS 5190- to a bare
ksw
ametal
gen AG does
part of the body. ol not
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ed nte
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th
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– Remove cotter -2- from shaft -1- of fuelssextractor - VAS 5190- . c
ce
e
nl
pt
du
– At distance -a- = 1,200 mm from end, mark extraction hose
an
itte
with insulating tape -arrow-.
y li
erm
ab
ility
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, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
– Remove filler cap from fuel tank filler neck.

nf
ercia
– Screw shaft end -1- of fuel extractor unit - VAS 5190- onto fuel
or
filler neck.
m
m
atio
m
– Push extraction hose into fuel tank until marking on hose

o
n in
or c
-arrow- coincides with shaft end.

thi
te
sd
iva
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f
en
ng
t.
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Cop py
t. rig
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co lksw
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Prote AG.
4. Parts of fuel supply system (Touran) 171

Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran ag2003 ➤olkswagen AG doe
en AG. V
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by
Vol t gu
a
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Note
ce
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nl
pt
du
an
itte
A ball valve -2- is located at the bottom of the filler neck in the fuel
y li
erm
ab
tank -1-; it must not be damaged by the extraction hose -3-.
ility
ot p
Therefore push hose into filler neck only as far as marking
wit
, is n
-arrow-.
h re
hole
spec
– Drain fuel tank as much as possible through fuel filler neck.
es, in part or in w
t to the co
– Carefully pull out extraction hose.
rrectness of i
Note
l purpos
♦ When no more fuel is extracted, the tank is emptied just

enough for the sender flange to be opened without danger.
nform
ercia
The tank may be removed while containing remaining fuel.

m
at
om
♦ If work must be performed on fuel pump or fuel tank sender,
ion
c
proceed as follows:
in t
or
his
ate
do
priv
cum
or

f
en
ng
t.
yi Co
op py
– Fold rear seats forwards.
t. C rig
gh ht
pyri by
Vo
o
c by lksw
cted agen
repairs, interior; Rep. gr. 70 ; Load and luggage compartment Prote AG.
WARNING

nection.
– Pull connector and fuel lines off flange.
Note
– Open locking ring using union nut tool - 3217- .

– Raise fuel delivery unit.
If fuel tank needed only to be emptied, install fuel delivery unit
again ⇒ page 176 .

4.3 Removing and installing fuel tank

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
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aut ra
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Removing s
ce
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un
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– Note safety precautions before starting work ⇒ page 144 .
an
d
itte
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erm
ab
ility
ot p
wit
is n
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ole,
Note
spec
t to the co
coding first if necessary. rrectne
♦ When lowering fuel tank, guide it carefully to prevent damage.
ss

o
cial p

inform
mer
atio
m

o
n
c
i
or

thi
te
sd
a

iv
o
pr

um
r
fo
en
ng
t.
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Cop py
ht. rig
– Pull connector off flange. rig ht
py by
co Vo
by lksw
– Remove fuel flap unit. ⇒ General body repairs, exterior; Rep. cted agen
Prote AG.
gr. 55 ; Fuel flap unit
– Draining fuel tank ⇒ page 170
– Remove rear right wheel housing liner: ⇒ General body re‐
housing liner .

– Disconnect fuel lines at front right of fuel tank.
Note
– If vehicle has supplementary heating, separate connector to

metering pump and unclip wire. ⇒ Supplementary heating;
Rep. gr. 82 ; Removing and installing metering pump -V54
– Remove bolts -A- and remove heat shield for fuel tank.
– Support fuel tank using engine and gearbox jack - V.A.G 1383/
A- .
– Remove securing bolts -B- and remove retaining strap.

– Slowly lower fuel tank and pull it forwards. n AG. Volkswagen AG
wage does
– Tilt fuel tank to get it past rear axle. Volks not
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ed ran
Installing ris tee
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Install in reverse order. In thes process, note the following:
ce
le
un
pt
♦ Install breather and fuel hoses free of kinks.

an
d
itte
y li
erm
ab

ility
ot p
wit
is n
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ole,
spec
♦ Clip supply and return lines onto fuel tank.

t to the co

rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
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fo
en
ng
t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

1 - Upper part of fuel filter

❑ Observe various types
⇒ page 175
2 - Fuel temperature sender -
G81-
❑ Installed in engine re‐
turn line
3 - Seal n AG. Volkswagen AG do
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❑ Renew yV
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4 - Filter insert ir se tee
tho
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❑ Observe change
ss inter‐
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vals.
ce
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nl
pt
du
an
5 - Seal
itte
y li
erm
ab
❑ Renew
ility
ot p
wit
6 - Fuel filter lower part
, is n
h re
hole
7 - 8 Nm
spec
es, in part or in w
8 - Bracket
t to the co
9 - Seal
❑ Renew
rrectness of i
10 - Retaining clip
l purpos
❑ Check for secure seat‐

ing.
nf
ercia
or
11 - Connection for fuel tem‐
m
m
atio
perature sender - G81-
om
n in
or c
12 - From tandem pump

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4.4.1 Upper part of fuel filter
Type A ⇒ page 175
Type B ⇒ page 176
1 - 8 Nm
renew seal)
for secure seating.
secure seating.
secure seating.
secure seating.


1 - 5 Nm
secure seating.
for secure seating.
secure seating.
secure seating.

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Note
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nf
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♦ Tighten fuel cooler securing nuts to 15 Nm.

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4.6 Removing and installing fuel delivery

unit

♦ Union nut tool - 3217-
AG. Volkswagen AG d
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Observe safety precautions ⇒ page 144 .
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– Pull 5-pin connector and fuel lines off flange.
Note
WARNING
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♦ The fuel system is alsosunder
ed
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the system, place cloths
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ss
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– Unscrew union nut with union nut tool - 3217- wrench .
h re
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spec
– Pull fuel delivery unit and seal out of the opening in fuel tank.
t to the co
Note
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posal.
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Installing
form
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atio
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livery unit.
♦ After installing fuel delivery unit, check that the supply, return
and breather lines are still clipped onto the fuel tank.
♦ Note installation position of fuel delivery unit flange: mark on
flange must align with mark on fuel tank -arrows-.
4.7 Removing and installing fuel gauge

sender
Removing

– Release connector lugs on lines -3- and -4- and pull off.
– Lift retaining tabs -1- and -2- using
olkswagen AaGscrewdriver and pull off
fuel gauge sender en AG. V
agdownwards -arrows-.
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Installing ised b ara
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– Insert
sa
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fuel sender into guides on fuel delivery unit andr a press
c
upwards until it engages.
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Note
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Special tools and workshop equipment required n in
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Test prerequisite:
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button.
min. 0.5 bar.
unit ⇒ page 188 .
– If the specifications are attained, check tandem pump to en‐
sure the fuel filter is not blocked ⇒ page 204 .
– If the tandem pump values are OK, check fuel pump delivery
rate ⇒ page 180 .


AG. Volkswagen AG d
Test prerequisite: agen oes
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• Fuses must be OK. orise nte
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Note

– Pull fuel supply line (black or black marking) -A- off fuel deliv‐
ery unit.
Note

– Check voltage supply ⇒ page 181 and current draw

G. Volkswage nA n AG d
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♦ Pickup clamp -y V.A.G
Vol
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♦ Test instrument
tho
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or
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Test prerequisites
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a battery charger.
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about 2 seconds.
– Switch off ignition.

– Connect test instrument adapter/DSO (5-pin) - VAS 5565- be‐

tween connector and flange.
Note
– Read voltage value on hand-held multimeter - V.A.G 1526D- :

Specification = battery voltage.
If no voltage is present:
– Check activation of fuel pump relay agand
en AGwiring
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agean
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does or
olksw
short circuit ⇒ Vehicle diagnostic tester. not
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Voltage supply OK: thoris nte
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au ac
– Remove fuel delivery
ss unit ⇒ page 188 .
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4.8.4 Checking current draw of fuel pump t to the co

rrectness of i

1526B/2-
l purpos

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Note
or
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The battery voltage and the diesel fuel temperature have a great
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Test prerequisites Prote
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agen

72 ; Rear seats .

– Pull connector -C- off flange.
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connected to red terminal with lettering “pickup clamp” of test in‐
nform
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strument adapter/DSO (5-pin) - VAS 5565- .

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– Switch on ignition.
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– Renew fuel delivery unit ⇒ page 188 .

5 Parts of fuel supply system (Passat)

page 145
⇒ “5.1 Fuel tank, vehicles with front-wheel drive”, page 184
⇒ “5.2 Emptying fuel tank, vehicles with front-wheel drive”,
page 191
5.1 Fuel tank, vehicles with front-wheel

drive olkswage
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⇒ “5.1.1 Assembly overview - fuel tank”, page 184rised nte
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⇒ “5.1.3 Removing and installing fuel deliveryssunit”,
au page 188 ra
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5.1.1 Assembly overview - fuel tank

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1 - Cap
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2 - 1.5 Nm
ole,
spec
3 - Tank flap unit
t to the co
❑ With rubber cup
⇒ General body repairs,
rrectne
exterior; Rep. gr. 55 ;
Tank flap unit
ss o
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form
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5 - Elbow
om
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6 - 10 Nm
thi
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7 - Fuel tank
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❑ Removing and installing cted agen
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⇒ page 186
❑ Emptying fuel tank
⇒ page 191 .
8 - Securing strap
tion
9 - Heat shield
❑ For fuel tank
10 - Lock washer, 2.5 Nm
11 - 25 Nm
❑ Renew
12 - Metering pump - V54-
For supplementary heater

❑ Removing and installing ⇒ Heating, air conditioning system; Rep. gr. 82 .
13 - Seal
❑ Renew
❑ When installing, fit dry in fuel tank opening
❑ Moisten with fuel only when installing flange
❑ With fuel gauge sender (G)
❑ Checking fuel pump ⇒ page 193
❑ Removing and installing fuel gauge sender ⇒ page 191
15 - Suction-jet pump
❑ Clean strainer if soiled
❑ Not necessarily installed
16 - Flange AG. Volkswagen AG d
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❑ For fuel delivery unit Volksw
oes
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❑ Note installation positionriseof flange on fuel tank ⇒ page 186
d
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17 - Locking ring, 110 Nmss au ra
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❑ Remove and install using wrench - 3087-
itte
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18 - Supply line
ility
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❑ For auxiliary heater
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❑ To metering pump - V54-
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es, in part or in w
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19 - Return line rrectness of i
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20 - Supply line
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❑ To fuel filter
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5. Parts of fuel supply system (Passat) 185

Installation position of fuel delivery unit

Marking -4- on flange points opposite direction of travel.
Note
The fuel delivery unit flange can be installed only in this position.
Connect black supply line -1- with »arrow« to union on flange.

Return line -2- (blue or with blue marking) to connection marked
»-R-«.
Black supply line -3- to metering pump - V54- for auxiliary heater.
Note
After installing fuel delivery unit flange, check that fuel lines are
still clipped onto fuel tank.

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Removing
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Note
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♦ The rear axle must be lowered to remove the fuel tank.

r
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s
♦ Before disconnecting battery, open fuel tank flap and if nec‐

iva
do
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essary remove wheel bolt lock adapter from luggage compart‐

rp
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186
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Rep. gr.20 - Fuel supply system Prote AG.

Note

AG. Volkswagen AG d
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♦ When lowering fuel tank, guide
Vol
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oes
not
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– With the ignition switched
tho off, disconnect battery earth strap. or
au ac
ss
– Remove rear bench seat ⇒ General body repairs, interior;
ce
e
nl
Rep. gr. 72 ; Rear seat; Removing and installing bench seat .
pt
du
an
itte
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erm
ab
ility
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– Pull 5-pin connector -5- off fuel delivery unit flange.
wit
, is n
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– Open fuel tank filler flap.
hole
spec
– Unscrew securing bolt and remove tank flap unit with rubber
es, in part or in w
t to the co
cup ⇒ General body repairs, exterior; Rep. gr. 55 ; Tank flap
unit .
– Empty fuel tank ⇒ page 191 .
rrectness of i
– Remove right rear wheel.
l purpos
– Remove rear right wheel housing liner ⇒ General body re‐

nform
ercia
housing liner .
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– Unclip ABS sensor wiring on fuel tank filler neck -arrows-.

WARNING

– Separate return line -1- and supply line -2- at connections.

– Separate fuel line -3- for metering pump - V54- at connections.
Note
Press in securing ring to release fuel lines. agen

AG. Volkswagen AG d
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olksw not
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– Pull connector -arrow- off metering pump - V54- r.ised
nte
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– Support rear axle using engine and gearboxsjack
s a - V.A.G 1383
u ra
c
A- .
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le
un
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– Remove securing bolts -arrows- and lower rear axle.
rm
ab
pe
ility
– Then support fuel tank using engine and gearbox jack - V.A.G
ot
wit
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1383 A- .
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
– Remove securing strap bolts.
a
com
tion in
– Slowly lower fuel tank. When doing this, pull fuel tank forwards,
r
te o
thi
turn and guide filler neck between rear axle and body.
s
iva
do
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Installing
um
fo
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t.
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Cop py
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– Tighten bolts of rear axle to body ⇒ Running gear, axles,
gh ht
pyri by
steering; Rep. gr. 42 .
co Vo
by lksw
cted agen
Prote AG.
♦ Fuel lines are to be installed free of kinks.
♦ Ensure that line connections are tight.
♦ Connections for fuel lines must engage audibly when joined.
♦ Check earth connection between body and filler neck for prop‐
er seating.
♦ Clip fuel lines onto fuel tank.
5.1.3 Removing and installing fuel delivery

unit

Removing
theft coding.
– With the ignition switched off, disconnect battery earth strap.
AG. Volkswagen AG d
agen
– The fuel tank must not be more than 1/2Vofull
lkswwhen removing
oes
not
gu
by
the suction-jet pump. Empty fuel tank
ris if necessary
ed ara
nte
⇒ page 191 . utho eo
ra
sa c
– Remove rear bench seat ⇒ General
s
body repairs, interior;
ce
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nl

pt
du
an
itte
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erm
ab
ility
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– Pull supply line -1-, return line -2-, supply line -3- to metering
wit
, is n
pump - V54- and 5-pin connector -5- off fuel delivery unit
h re
flange.
hole
spec
es, in part or in w
t to the co
Note
rrectness of i
Press in securing ring to release fuel lines.

l purpos
nform
mercia
at
om
ion
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189
by c lksw
cted
5. Parts of fuel supply system (Passat)
agen
Prote AG.

AG. Volkswagen AG d
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– Pull fuel line -1- off suction-jet pump (if fitted).
aut
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ra
ss c
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nl
pt
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Note
an
itte
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erm
ab
ility
ot p
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– Press tab -2- of suction-jet pump in -direction of arrow- and
hole
spec
unclip from fuel delivery unit
es, in part or in w
t to the co
– Pull fuel delivery unit along with suction-jet pump out of open‐
ing in fuel tank.
rrectness of i
Note
l purpos
nf
ercia
posal.
orm
m
atio
m
Installing
o
n in
or c
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– Installing the fuel delivery unit is carried out in reverse order

t
sd
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of removal.
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♦ For fuel delivery units of the new generation the suction jet
by c lksw
cted agen
pump is no longer available. If the fuel delivery unit is to be
Prote AG.
renewed, remove suction jet pump.

♦ When inserting fuel delivery unit, ensure that fuel gauge send‐
er is not bent.
fuel tank.
livery unit.
♦ Fuel lines are to be installed free of kinks.
♦ Connections for fuel lines must engage audibly when joined.
♦ After installing fuel delivery unit, check that fuel lines are still
clipped onto fuel tank.
♦ Observe installation position of fuel delivery unit ⇒ page 186 .

5.1.4 Removing and installing fuel gauge

sender
Removing
– Release connector tabs of wires -arrows- and pull them off.
– Lift up retaining tabs -1- using a screwdriver and pull off fuel
gauge sender upwards in direction of -arrow-. wage
es ks not
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Installing ed by ara
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ris
– Insert fuel gauge sender into guides tho delivery
onaufuel unit and
eo
ra
press downwards until it engages. ss c
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le
un
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– Install fuel delivery unit ⇒ page 188 .
an
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spec
5.2 Emptying fuel tank, vehicles with front-
t to the co
wheel drive
rrectne
ss o
cial p
f inform
mer
atio
om
n
c
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♦ Fuel extractor - VAS 5190-

Emptying fuel tank if more than 3/4 full ⇒ page 192
Emptying fuel tank if less than 3/4 full ⇒ page 192

full
Procedure
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gen AG does
Note safety precautions before beginning
Vol
kswork
wa ⇒ page 144 . not
y gu
db ara
– At distance -a- = 990 mm fromoriend,
se mark extraction hose with nte
eo
insulating tape -arrow-. auth ra
ss c
– Open fuel tank filler flap.
ce
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nl
pt
du
an
– Push extraction hose of fuel extractor - VAS 5190- into fuel
itte
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filler neck until the previously made marking aligns with filler
ab
ility
neck.
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Note
es, in part or in w
t to the co
♦ The shaft piece -1- is not used.
♦ A flap is located on the lower end of the fuel filler neck, this
rrectness of i
must not be damaged by the extraction hose. Therefore, push
the extraction hose into the fuel filler neck only up to previously
l purpos
made marking.
nf
ercia
– Empty fuel tank as far as possible.
orm
m
atio
– Then carefully remove extraction hose.
om
n in
or c
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Note
iv
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When no more fuel is extracted, the tank is emptied just enough

t.
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op
for the sender flange to be opened without danger. The tank may C py
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be removed while containing remaining fuel.
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Procedure
Note safety precautions before beginning work ⇒ page 144 .
– Remove rear bench seat ⇒ General body repairs, interior;
WARNING

4-cylinder
AG. Volkswagdiesel
en A engine (1.9 l engine) - Edition 12.2013
n G do
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olks o
– Pull supply line -1-, return line y supply line -3- to metering t gua
V
-2-,
b
ed ran
pump - V54- and 5-pin connector
ho
ris -5- off fuel delivery unit tee
flange. aut or
ac
ss
ce
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nl
pt
du
an
Note
itte
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erm
ab
ility
ot p
Press in securing ring to release fuel lines.
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos

nform
ercia

m
If fuel tank needed only to be emptied, reinstall sender flange
at
om
io
⇒ page 188 .
n
c
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or
his
ate
do
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for
en
ng
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Note


Test prerequisite:


button.
min. 0.5 bar.
unit ⇒ page 188 . en AG. V
olkswagen AG
ag does
lksw n
– If the specificationsy V are attained, check tandem pump
o ot g
ua to en‐
db
sure the fuelorfilter
is e is not blocked ⇒ page 204 . ran
te
h eo
ut
– If the tandem
ss
a pump values are OK, check fuel pump delivery
ra
c
rate ⇒ page 194 .
ce
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rm
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es, in part or in w

t to the co

Test prerequisite:
rrectness of i

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tion in
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Note

Note
– Pull fuel supply line (black or black marking) -A- offolfuel
ksw deliv‐
age es n
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ery unit. db
y V ua
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e
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– Connect -VAS 6550/1- pressure tester line
ut to fuel supply
ho -A-. or
a ac
ss
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un
pt
an

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itte
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rm
ab
pe
ility
ot
wit
, is n
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Note
hole
spec
es, in part or in w

t to the co

rrectness of i

l purpos
– Check voltage supply ⇒ page 195 . Measure current draw

nform
mercia
a
com

ion in
r
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♦ Pickup clamp - V.A.G 1526B/2-
Co
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AG.
5. Parts of fuel supply system (Passat)
Test prerequisites
a battery charger.
72 ; Rear seats .
about 2 seconds.
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– Connect test instrument adapter/DSO
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Rep. gr.20 - Fuel supply system

Note
– Read voltage value on hand-held multimeter - V.A.G 1526D- :

Specification = battery voltage. n AG. Volkswagen A
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If no voltage is present: y Vol ot g
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– Check activation of fuelthorpump relay and wiring for an open or tee
or
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Voltage supply OK:

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5.3.4 Checking current draw of fuel pump
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1526B/2-
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Test prerequisites
72 ; Rear seats .

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– Pull connector -C- ooff
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nform
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5565- .
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his
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connected to red cable with lettering “pickup clamp (Stromzange)”

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of test instrument adapter/DSO (5-pin) - VAS 5565- . C py
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Note

– Renew fuel delivery unit ⇒ page 188 .
Note
Note that there are different versions of fuel filter upper part
⇒ page 200 .

1 - Return line
❑ To fuel cooler
ing
2 - 6 Nm
3 - Washer
4 - Supply line
❑ From fuel tank
❑ White or with white
marking
5 - Return line
❑ From tandem pump
❑ Blue marking
6 - Supply line
❑ To tandem pump
❑ White marking
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11 - Lower part of fuel filter

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12 - 10 Nm
13 - Connection for fuel temperature sender - G81-
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14 - Retaining clip
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15 - O-ring
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❑ Renew
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5.4.1 Upper part of fuel filter

Type A ⇒ page 200
Type B ⇒ page 200
1 - 8 Nm
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for secure seating.
secure seating.
secure seating.
secure seating.

1 - 5 Nm
secure seating. . Volkswag AG en AG
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3 - Fuel supply line from fuel
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Removing t. Cop py
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Note

– Pull fuel lines -1- and -2- off fuel cooler.
Installing
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♦ Tighten fuel
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6 Accelerator mechanism autho eo
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Removing and installing accelerator mechanism ⇒ page 202 .
hole
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1 - Connector
❑ Black, 6-pin.
rrectness of i
2 - Accelerator position sender
- G79-
❑ Not adjustable. l purpos
❑ The accelerator position
nform
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sender passes the posi‐

tion of the accelerator
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4 - Cap Prote AG.
6.1.1 Removing and installing accelerator

module
♦ Release tool - T 10269- (for right-hand drive vehicles -
T10297- ).

Removing
– Lever off cap ⇒ Item 4 (page 202) using a screwdriver.

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– To remove accelerator module,ss push release tool - T 10238-
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– To remove accelerator module, push release tool - T 10269-

(for right-hand drive models -T10297- ) into openings provided
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Continuation for all vehicle types:

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– Pull connector off accelerator module.

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– Pull out accelerator pedal module vertically.

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agen
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– Attach connector and wiring guide to accelerator pedal mod‐

ule.
– Press accelerator pedal module onto securing pins.
– Insert centring pin into hole in vehicle floor.
– Secure accelerator module with securing bolt -3-. Specified
torque: 9 Nm
– Attach cap.
– Install steering column cover.
6. Accelerator mechanism 203

7 Tandem pump swage

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⇒ “7.1 Checking tandem pump”, page 204 ed by ua
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⇒ “7.2 Removing and installing tandem apump”,
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page 207 or
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♦ Tandem pump tester - VAS 5187-
rrectness of i
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Test prerequisites
• Coolant temperature must be at least 85°C.
• Unit injectors OK.
• Fuel filter and fuel lines must not be blocked.

Procedure
– Remove air filter housing.
– Remove screw plug -arrow-.
– Connect tandem pump tester - VAS 5187- if necessary, with

adapter - VAS 5187/7- or banjo bolt with seal - VAS 5187/1A-
as shown.
– Re-install the air filter housing.
– Start engine and raise engine speed to 4000 rpm.
– Observe pressure indicated on pressure gauge. agen AG. Volkswagen AG do
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Specification: at least 7.5 bar, tandem pumpedOK.
by ua
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If the specification is not attained: utho eo
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– Renew fuel filter.
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– Repeat check.
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If the specifications are still not attained:
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– Using a hose clip, clamp-off return line between fuel filter and
h re
tandem pump.
ole,
spec
– Repeat check.
t to the co
If specification is now obtained:
– Tandem pump is OK. Renew unit injector O-rings.
rrectne
ss
– Renew tandem pump ⇒ page 207 .

o
cial p
f inform
mer
Note
atio
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n
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After removing pressure gauge, tighten plug to 25 Nm. Always

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7.1.2 Checking for internal leaks Cop py
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Note
Prote AG.
The tandem pump must be checked for internal leaks between

fuel side and oil side after reinstalling a used tandem pump, e.g.
after renewing or repairing a cylinder head and/or when installing
a "short" engine. When leaking it is possible for the fuel to mix
with the oil which may cause the engine to fail.
7. Tandem pump 205

♦ Tester - V.A.G 1687-
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Procedure
rm
ab
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– Pull fuel supply hose (white marking) and fuel return hose
ot
wit
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(blue marking) off tandem pump.
h re
hole
spec
– Seal fuel return union on tandem pump with a plug. Secure
es, in part or in w
sealing plug with a spring-type clip.
t to the co
Prepare test unit - V.A.G 1687- as follows:
– Unscrew pressure control valve -2- and close valves -3- and
rrectness of i
-4-.
l purpos
– Connect test connection -5- to fuel supply union of tandem

pump using a commercially available compressed air connec‐
nform
ercia
tion and a section of fuel hose. Use a spring-type clip to secure.

m
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Note
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To turn the pressure control valve -2- the knob must be pulled
r
rp
cum
upwards.
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– Connect compressed air hose -1- (compressed air source) to

charge air system tester - V.A.G 1687- .
Note
If there is water in the sight glass, drain at water drain screw -6-.
– Open valve -3-.

– Adjust pressure to 1.0 bar with pressure regulating valve -2-.
Caution
The maximum test pressure is 1.3 bar and this must not be
exceeded.
– Open valve -4- and wait until the test circuit is filled. If neces‐
sary readjust pressure to 1.0 bar.
– Close valve -3- to retain pressure and observe the pressure
drop over a period of 1 minute.
If the pressure does not drop the tandem pump can be reused, if
the pressure drops the tandem pump must be renewed.

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ra
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ss 4-cylinder diesel engine (1.9 l engine)c - Edition 12.2013
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nl
pt
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7.2 Removing and installing tandem pump
itte
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DANGER!
wit
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spec
The tandem pump may, under no circumstances, be disman‐
es, in part or in w
tled as the vacuum part could otherwise malfunction. This
t to the co
would result in the failure of the brake booster.
rrectness of i
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equipment required
nform
ercia

1331-
m
at
om
io
♦ Hand vacuum pump with
n
c
in t
r
accessories - V.A.G 1390-

o
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ate
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♦ Water drainage container -

p
cum
or
V.A.G 1390/1-
f
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t.
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♦ Spring-type clip pliers - Cop py
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VAS 5024 A- opyri
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Prote AG.
7. Tandem pump 207

7.2.1 Removing
– Pull supply hose -1- (white marking) and return hose -2- (blue
marking) off fuel filter.
– Connect hand vacuum pump with accessories - V.A.G 1390-
and water drainage container - V.A.G 1390/1- to return hose
-2-.
Be careful that no fuel is sucked into hand vacuum pump.
– Operate lever of hand vacuum pump until no more fuel comes
out of return hose.
– Remove air filter housing ⇒ page 246 .
AG. Volkswagen AG d
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– Pull vacuum hose leading to brake servo -arrow- off tandem. d by gu
ara
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– Pull fuel supply hose -2- off tandem pump.
l purpos
– Pull fuel return hose -1- (marked blue) off fuel line.
nf
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– Unscrew bolts -arrows-.
co Vo
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– Remove tandem pump from cylinder head.
7.2.2 Installing
note the following:

AG. Volkswagen AG d
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olkswGolf 2004 ➤ , Golf Plus n2005
ot g ➤ , Passat 2006 ➤ , Touran 2003 ➤
byV ua
ris
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4-cylinder diesel engine
ran
tee (1.9 l engine) - Edition 12.2013
tho
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ss
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nl
Note
pt
du
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itte
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♦ Renew tandem pump gaskets.
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wit
♦ Ensure that tandem pump follower is seated properly in cam‐
, is n
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shaft.
hole
spec
♦ Secure all hose connections with the same types of hose clips
es, in part or in w
t to the co
as original equipment ⇒ Electronic Parts Catalogue .
– Install tandem pump and tighten upper securing bolts to
rrectness of i
20 Nm.
l purpos
– Tighten lower securing bolts to 10 Nm.

– Attach return hose (blue marking) to return connection of tan‐
nf
ercia
dem pump.
orm
m
atio
– Attach supply hose (white marking) to supply connection of
om
n in
tandem pump.
or c
thi
te
– Connect vacuum line leading from brake servo to tandem
sd
iva
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pump.
rp
cu
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f
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ng
– Attach supply hose -1- (white marking) to fuel filter.

t.
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Cop py
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and water drainage container - V.A.G 1390/1- to return hose copy Vo
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-2- (blue marking) of fuel filter. cted agen
Prote AG.
– Operate hand vacuum pump until fuel comes out of return

hose. Be careful that no fuel is sucked into hand vacuum
pump.
– Attach return hose (blue marking) to fuel filter.
– Carry out a leakage test ⇒ page 205 .
7. Tandem pump 209

AG. Volkswagen AG d
4-cylinder diesel engine (1.9 l engine) - Edition 12.2013 ksw
agen oes
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21 – Turbocharging/supercharging
ss
au
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pt
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1 Turbocharger
itte
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⇒ “1.1 Safety precautions”, page 210
ot p
wit
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hole
spec
⇒ “1.3 Assembly overview - turbocharger”, page 211
es, in part or in w
t to the co
⇒ “1.4 Removing and installing turbocharger”, page 224
⇒ “1.5 Vacuum hose schematic diagram”, page 226
rrectness of i
1.1 Safety precautions
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WARNING
nf
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orm
m
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m

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or c
tions:
thi
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t.
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♦ Ensure that there is sufficient clearance to all moving or copy Vo
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hot components. cted agen
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rear seat and operated by a second person from this location.
If test and measuring instruments are operated from front pas‐
senger seat and the vehicle is involved in an accident, there is a
possibility that the person sitting in this seat may receive serious
injuries when the airbag is triggered.

When working on the turbocharger, pay careful attention to the
following rules for cleanliness:
connecting.
lint-free cloths.
tool boxes etc.).
♦ Existing transport and protective packaging and sealing caps
must only be removed immediately prior to installation.
♦ When making repairs, remove oil from connection and hose
ends.
essary.
210 Rep. gr.21 - Turbocharging/supercharging

1.3 Assembly overview - turbocharger
Note
♦ All hose connections are secured.

♦ Charge air system must be free of leaks.
♦ Renew self-locking nuts.
♦ Before screwing on oil supply line, fill turbocharger at connec‐
tion with engine oil.
Volkswa
♦ After installing turbocharger,
swa
gen AG run engine
.
for
gen AG
doeabout
s 1 minute at
idling speed tobyensure
Volk
that oil is supplied to turbocharger.
not
gu
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⇒ “1.2 Rulesau for cleanliness”, page 210
or
ac
ss
ce
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un
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⇒ “1.3.1 Engine codes AVQ BJB, BKC, BRU, BXE and BXF”,
y li
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page 211
ility
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⇒ “1.3.2 Engine codes BLS and BXJ”, page 214
wit
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⇒ “1.3.3 Changing and adjusting vacuum unit on turbocharger -
spec
vehicles with engine code: BLS, BXJ from model year 2008 only”,
page 216
1.3.1 Engine codes AVQ BJB, BKC, BRU, BXE and BXF t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
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sd
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fo
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t.
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Cop py
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rig ht
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co Vo
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Prote AG.
1. Turbocharger 211
1 - 10 Nm
3 - Oil supply line
❑ Before installing oil sup‐
ply line, ensure that it is
not blocked.
❑ Before installing, fill tur‐
bocharger with engine
oil through oil supply line
connection.
⇒ page 118
5 - Seal
❑ Renew
tion
6 - Washer
7 - 25 Nm
❑ Renew
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8 - Support ksw
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❑ Between turbocharger ed by gu
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and cylinder block. horis nte
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9 - 40 Nm ss c
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❑ First hand tighten all
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10 - Connecting pipe
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❑ Air filter/turbocharger
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es, in part or in w
12 - Seal
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❑ Renew
13 - Seal
rrectness of i
❑ Renew
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14 - Union, 40 Nm
nf
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15 - Oil return line

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❑ To cylinder block
atio
om
❑ Tighten union nut to 30 Nm

n in
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16 - 17 Nm
t
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17 - Vacuum hose
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❑ To solenoid valve block
Co
Cop py
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18 - Turbocharger
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❑ Can only be renewed with exhaust manifold.
lksw
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❑ To remove turbocharger, remove right drive shaft ⇒ Running gear, axles, steering; Rep. gr. 40 ; Re‐
moving and installing drive shafts .
19 - 20 Nm
❑ First hand tighten all bolts
20 - 20 Nm
❑ Renew

21 - Heat shield
22 - Seal
❑ Renew
23 - Clamp, 7 Nm
24 - Front exhaust pipe
25 - Bracket
❑ For oil supply line ⇒ Item 3 (page 212) .
❑ Before installing, secure oil supply line
26 - 22 Nm
❑ Renew
❑ To bypass flap
28 - Union, 30 Nm
❑ Renew
❑ Coat threads and bolt head seating surface with “G 052 112 A3”.
AG. Volkswagen AG d
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spec
es, in part or in w
t to the co
rrectness of i
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ion
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ate
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1. Turbocharger 213
1.3.2 Engine codes BLS and BXJ
1 - 10 Nm
2 - Bracket
AG. Volkswagen AG d
3 - Heat shield ksw
agen oes
not
Vol
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4 - Oil supply hose ise
d b ara
nte
or
❑ To oil supply line con‐ auth eo
ra
nection on turbocharger ss c
ce
le
❑ Before installing oil sup‐
un
pt
an
d
ply line, ensure that it is
itte
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not blocked.
rm
ab
pe
ility
❑ Before installing, fill tur‐ ot
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bocharger via oil supply
h re
hose with engine oil
hole
spec
es, in part or in w
5 - Turbocharger
t to the co
❑ Can only be renewed
with exhaust manifold.
rrectness of i
⇒ page 224
l purpos
6 - Vacuum hose
nform
ercia
7 - Seal
❑ Renew
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8 - To particulate filter
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9 - Clamp, 7 Nm
n
t.
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op
❑ For turbocharger/partic‐
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cted
10 - Exhaust manifold
agen
Prote AG.
❑ Can only be renewed to‐

gether with turbocharg‐
er
11 - 25 Nm
❑ Renew
12 - 25 Nm
13 - Seal
❑ Renew
❑ For exhaust gas recirculation
❑ Assembly overview - parts of exhaust gas recirculation ⇒ page 279
15 - 25 Nm
❑ Renew
16 - 15 Nm
17 - O-ring
❑ Renew
18 - Banjo bolt, 60 Nm
❑ Renew
19 - Support
❑ For turbocharger

❑ With oil return line
20 - Exhaust gas temperature sender bank 1 - G235- , 45 Nm
❑ Lubricate thread of sender using high-temperature paste - G 052 112 A3-
❑ To remove and install, use a wrench - T10395 - from supplement tool set 19mm.
❑ Socket - T40055- may also be used to remove and install.
21 - Heat shield
22 - Connection
❑ For intake hose for air filter/turbocharger
❑ Assembly overview - air filter ⇒ page 246
23 - 9 Nm
24 - 10 Nm
Installation position of exhaust gas temperature sender with an‐

gled cable guide
Note
When the exhaust gas temperature sender with angled cable

guide is being removed, the distance -a- of 3 ... 5 mm to screw
support against turbocharger.
AG. Volkswagen AG d
agen oes
olksw not
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or eo
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aut ra
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t to the co
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1. Turbocharger 215
1.3.3 Changing and adjusting vacuum unit on turbocharger - vehicles with engine
code: BLS, BXJ from model year 2008 only
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pt
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ab
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es, in part or in w
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equipment required
♦ Hand vacuum pump - VAS
6213-
♦ Turbocharger tester -
V.A.G 1397A-
♦ Pressure control valve -
VAS 6342-
♦ Ring spanner - T10423-
♦ Socket AF 10 mm -
T10454-
♦ 14 mm open-end spanner -
T10461- agen
AG. Volkswagen AG d
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aut ra
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nl
pt
du
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erm
ab
ility
ot p
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, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
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ion
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ate
do
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1. Turbocharger 217
Caution
The special tools indicated, in particular the socket inset, -

T10454- is designed solely for use according to the following
work instructions and must not be used for other threaded con‐
nections. There is a danger of deformation if high torques are
applied.
Note
A replacement parts kit for changing the vacuum unit is available

⇒ Electronic Parts Catalogue .
Removing
Golf Plus, Touran
– To change vacuum unit, remove and install turbocharger
⇒ page 224 wage es n
olks o t gu
yV
db ara
Continuation for Golf, Passat rise nte
tho eo
– Remove engine cover. au ra
c
ss
ce
e
– Release clips -arrows- on sides of cover and pull cover off air
nl
pt
du
an
duct.
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ility
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spec
es, in part or in w
t to the co
rrectness of i
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– Unclip lower air duct -2- by releasing retaining clips on left and
nform
ercia
right -arrow A-.

m
at
om
– Unhook air duct from mountings -3-.

ion
c
in t
or
– To do this, swing air duct downwards and slightly to rear.

his
ate
do
riv
– Detach air pipe -1- from lower air duct -arrow B-.
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– Disconnect electrical connector -1- from air mass meter -

G70- .
– Pull off vent hose -3- and also air duct hose -2-.
– Remove bolt -4- and remove air filter housing.
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– Detachth hose -2- from crankcase breather.
o tee
or
au ac
ss
– Lay aside ventilation hose -4- and vacuum hoses -1- at air
ce
e
hose.
nl
pt
du
an
itte
y li
– Unscrew bolt -3-.
erm
ab
ility
ot p
– Swing air duct hose to rear and pull off of turbocharger.
wit
, is n
h re
– Seal opening in turbocharger with plug from spare-parts kit.
hole
spec
– Pull vacuum hose off turbocharger.
es, in part or in w
t to the co
rrectness of i
– Depending on version, unscrew securing nut -arrow- of con‐

l purpos
nection for oil supply line and/or vacuum line to cylinder head.
nf
ercia
Caution
rm
m
atio
om
When detaching the oil supply line, counterhold the connec‐

n in
or c
tion. Risk of damage as a consequence!

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Prote
– Counterhold connecting piece with 14mm open-end spanner
AG.
- T10461- and unscrew oil supply line -arrow- from turbo‐

charger.
– Seal oil supply opening in turbocharger with the plug from the
spare-parts kit.
1. Turbocharger 219
– Counterhold lock nut -B- with ring spanner - T10423- and un‐
screw securing nut -A- from the control rod using socket inset
- T10454- .
– Remove bolts -1-, remove bolt -2- and finally remove vacuum
unit -A-.
Installing
– Mark vacuum unit and control rod with colour -as shown-.
Note
The colour marking will indicate possible twisting of the control

rod after tightening and make correction possible.
. Volkswage n AG n AG d
wage oes
Volks not
gu
by ara
ed
Caution
oris nte
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th
au ra
c
ss
Only use new bolts and nuts from the spare-parts kit!
ce
le
un
pt
an
d
itte
y li
rm
ab
– If necessary, remove lower securing nut of control rod from

pe
ility
new vacuum unit.

ot
wit
, is n
h re
– Screw lock nut by hand onto control rod in direction of vacuum

hole
unit to stop.
spec
es, in part or in w
t to the co
– Push control rod through adjusting lever on turbocharger, fit

vacuum unit -A- and lock in place.
rrectness of i
– Start bolts -1- and -2- from repair kit.

l purpos
– Tighten bolts -1- and -2- to 8 Nm.

nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
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rp
cum
fo
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ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

AG. Volkswagen AG d
agen oes
olksw not
Golf 2004 ➤ ,d bGolfy V Plus 2005 ➤ , Passat 2006 ➤ gu, Touran 2003 ➤
ara
e
i4-cylinder
hor s diesel engine (1.9 l engine) - Edition
nte
e o 12.2013
aut ra
ss c
– Switch on turbocharger tester - V.A.G 1397A- and set sliding
ce
e
nl
switch to position “I”.
pt
du
an
itte
y li
– Subtract 600 mbar from atmospheric pressure displayed and
erm
ab
note value. (Value 1)
ility
ot p
wit
, is n
– Subtract 650 mbar from atmospheric pressure displayed and
h re
note value. (Value 2)
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
– Connect test and measuring instruments together as illustra‐

ted and connect to connection “I” -arrow- of turbocharger
nform
ercia
tester - V.A.G 1397A- and to turbocharger vacuum unit.

m
at
om
i
– Close lever -1- on pressure regulating valve - VAS 6342- .
on
c
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or
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ate
do
priv
cum
for
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ng
t.
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ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
– Move slide ring -1- on hand vacuum pump - VAS 6213- to po‐
sition -A- for “vacuum”.
Caution
Excessive pressure may damage the vacuum unit.

The pressure must not fall below the read atmospheric pres‐
sure minus 800 mbar.
Note
♦ An accuracy of +/- 20 mbar is adequate when setting value 2.
♦ Make sure that the turbocharger adjusting lever moves easily

along the control rod.
– Operate hand vacuum pump - VAS 6213- several times until

noted value 2 is attained on turbocharger tester - V.A.G
1397A- .
1. Turbocharger 221
– Open pressure regulating valve -1- until value 1 is set exactly.
– Screw nut -A- up a couple of threads on control rod.
AG. Volkswagen AG d
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– Hold adjusting lever -1- on »stop« of adjustment
hor screw -2- by eo
hand. aut ra
ss c
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le
un
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an
d
itte
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rm
ab
pe
ility
ot
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
Note
nform
ercia
♦ During the next step, ensure that the adjusting lever -1- re‐
mains against the adjustment screw -2- and is not already
m
a
com
ti
contacting the securing nut -A-.

on in
r
te o
thi
♦ In this case, screw back securing nut -A-.

s
iva
do
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Golf 2004 ➤ , Golf Plus 2005 ag➤ , GPassat
en A 2006
. Volkswa ➤do,eTouran 2003 ➤
gen AG
ksw s no
4-cylinder bdiesel
yV
ol
engine (1.9 l engine) - Edition t gu 12.2013
a
ed ran
oris tee
– Screw control rod lock nut -B- down slowly by au hand
th
until it or
ac
contacts adjusting lever -1-. Do not turn further.
ss
ce
e
nl
pt
– Screw securing nut -A- up on control rod until it lies against
du
an
itte
adjusting lever.
y li
erm
ab
ility
ot p
wit
, is n
Note
h re
hole
spec
Ensure control rod does not twist while tightening securing nut
es, in part or in w
t to the co
-A-.
– Counterhold lock nut -B- with ring spanner - T10423- and
rrectness of i
tighten securing nut -A- using socket inset - T10454- . l purpos
– Check colour marks on control rod. They must align

-as shown-.
nf
ercia
orm
m
atio
om
n in
or c
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sd
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Prote AG.
– Release vacuum, move slide ring -1- on hand vacuum pump

to position -B- for this, then move slide ring back to position
-A- again.
Note
There very little space between the cylinder head and the turbo‐
charger. Be you know exactly where the feeler gauge (0.05 mm)
must be positioned.
– The feeler gauge (0.05 mm) must be positioned between ad‐

justing lever and adjustment screw, as shown.
Note
The feeler gauge (0.05 mm) has a part number and must be or‐
dered from the ⇒ Electronic Parts Catalogue .
– Operate the hand vacuum pump - VAS 6213- until the feeler
gauge (0.05 mm) is pinched between adjusting lever and ad‐
justment screw.
Now the »noted value 1« +/- 20 mbar should appear on the tur‐
bocharger tester - V.A.G 1397A- .
Value OK.
1. Turbocharger 223
lkswage es n
o ot g
byV ua
d ran
ir se tee
o
Golf 2004 ➤ , Golf Plus 2005 ➤ au , Passat 2006 ➤ , Touran 2003 ➤
th or
ac
4-cylinder diesel engine (1.9 l engine) - Edition 12.2013 ss
ce
e
nl
pt
du
an
– Seal connection between control rod and securing nut with
itte
y li
sealing paint from the spare-parts kit.
erm
ab
ility
ot p
– Press locking plate by hand onto the control rod and turn 90°
wit
, is n
in the -direction of the arrow-.
h re
hole
spec
Value not OK.
es, in part or in w
t to the co
Repeat adjustment procedure.
Continuation
rrectness of i
l purpos
nf
ercia
o
– Counterhold connecting piece with 14 mm open-end spanner
rm
m
- T10461- and unscrew oil supply line -arrow- from turbo‐
atio
m
charger.
o
n in
or c
thi
te
sd
iva
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Cop py
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Prote AG.
– Depending on version, locate nut -arrow- for oil supply line

and/or vacuum line connection on cylinder head and tighten.
Golf Plus, Touran
– Install plenum chamber bulkhead. ⇒ General body repairs,
head .
– Complete the engine.
– Start engine and clear event memory ⇒ Vehicle diagnostic
tester.
1.4 Removing and installing turbocharger

♦ Lambda probe open ring spanner set - 3337-

♦ Tool set - T10395-
Caution
When a mechanical fault is found on the turbocharger, e.g. a

. Volkswagen AG
destroyed compressor kswimpeller,
agen AG it is not only sufficient
does to renew
the turbocharger.byTo
Volprevent this from causing further
not
gu damage,
perform the following repairs:
a
ed ran
ris te
tho eo
♦ Checkss
auair filter housing, air filter element and intake hoses
ra
c
for soiling.
ce
le
un
pt
♦ Check complete charged air routing and charge air cooler an
d
itte
y li
for foreign objects.
rm
ab
pe
ility
If foreign objects are found in the charge air system, the charg‐
ot
wit
, is n
ed air routing must be cleaned and the charge air cooler must
h re
be renewed, if necessary.
hole
spec
es, in part or in w
t to the co
Removing
rrectness of i
Rep. gr. 50 ; Body - front; Noise insulation .

l purpos
Vehicles with four-wheel drive:

– Remove front propshaft ⇒ Final drive 02D, 0AV; Rep. gr. 39 ;
nform
ercia

m
a
com

ion in
Rep. gr. 40 .
r
te o
thi
s
iva
Vehicles with particulate filter:

do
r
rp
cum
fo
– Pull electrical connector off exhaust gas pressure sensor 1 -

en
ng
t.
G450- in engine compartment and unscrew securing bolts.
yi Co
Cop py
ht. rig
– Separate electrical connectors to particulate filter.
rig ht
py by
co Vo
by lksw
– Remove subframe including steering and right drive shaft ⇒
cted agen
Prote AG.
Running gear, axles, steering; Rep. gr. 40 .
– Remove particulate filter.
– On vehicles with four-wheel drive remove bevel box to reach
threaded connection for turbocharger support ⇒ 6-speed
manual gearbox; Rep. gr. 34 ; Removing and installing bevel
box .
1. Turbocharger 225

– Disconnect fasteners -arrows- of coolant pipes for auxiliary
heater, if part of original equipment.

– Remove support and oil return line or combination support
⇒ Item 19 (page 214) for turbocharger.
– Remove connecting pipe to exhaust gas recirculation cooler.
– Separate charge pressure line from turbocharger.
AG. Volkswagen AG d
agen oes
– Pull vacuum hose off turbocharger. olksw not
V gu
d by ara
e
– Separate oil supply line from turbocharger. horis nte
eo
aut ra
– Unscrew securing bolts for exhaust manifold. ss c
ce
e
nl
pt
– Tilt the engine forwards in lower mounting and remove turbo‐
du
an
itte
charger with exhaust manifold downwards.
y li
erm
ab
ility
Installing
ot p
wit
, is n
– Install in reverse order.
h re
hole
spec
es, in part or in w
t to the co
Note
Torque setting of pendulum support ⇒ page 27 .
rrectness of i
l purpos
1.5 Vacuum hose schematic diagram
nf
ercia
⇒ “1.5.1 Vehicles with particulate filter”, page 226

orm
m
atio
⇒ “1.5.2 Vehicles without particulate filter”, page 228
om
n in
or c
1.5.1 Vehicles with particulate filter

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Prote AG.

1 - Turbocharger
2 - Connecting pipe air filter/
turbocharger
3 - Non-return valve
tion
4 - To brake servo
5 - Charge pressure control
solenoid valve - N75-
6 - Air filter
block
8 - Intake manifold
9 - Bypass flap
❑ For exhaust gas recircu‐
lation cooler AG. Volkswagen AG d
agen oes
lksw not
10 - Radiator by
Vo gu
ara
ed
❑ For exhaust gas recircu‐ho ris nte
eo
lation s aut ra
c
s
ce
le
un
pt
valve - N18-
an
d
itte
y li
rm
ab
pe
ility
cooler changeover valve -
ot
wit
, is n
N345-
h re
hole
spec
es, in part or in w
t to the co
tion
14 - Vacuum unit rrectness of i
❑ Turbocharger
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
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Cop py
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Prote AG.
1. Turbocharger 227
1.5.2 Vehicles without particulate filter
1 - Solenoid valve block

tion
3 - To brake servo
4 - Connecting pipe air filter/
turbocharger
5 - Air filter
6 - Intake manifold
block agen
AG. Volkswagen AG d
oes
olksw not
8 - Vacuum reservoired b y V gu
ara
ris nte
9 - Bypass flap autho eo
ra
s c
❑ For exhaust
s gas recircu‐
ce
le
lation cooler
un
pt
an
d
itte
y li
10 - Radiator
erm
ab
❑ For exhaust gas recircu‐ ility
ot p
lation wit
is n
h re
ole,

spec
valve - N18-
t to the co
12 - Turbocharger
rrectne

tion
ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
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Cop py
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co lksw
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Prote AG.

2 Charge air system

⇒ “2.1 Assembly overview - parts of charge air cooling”,
page 229
⇒ “2.2 Hose connections”, page 232
⇒ “2.3 Checking charge air system for leaks”, page 233
2.1 Assembly overview - parts of charge air

cooling
Note
♦ Charge air system must be free of leaks.

♦ When making repairs, remove oil from connection and hose
ends.
♦ All hose connections of charge air system are secured by
spring-type clips or by plug-in connectors.
♦ Checking charge air system for leaks ⇒ page 233
⇒ “2.1.1 Engine codes AVQ BJB, BKC, BRU, BXE and BXF”,
page 229
⇒ “2.2 Hose connections”, page 232
2.1.1 Engine codes AVQ BJB, BKC, BRU, BXE and BXF
Volkswag AG. en AG
agen does
olksw not
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rm
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ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
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do
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en
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Cop py
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by c lksw
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Prote AG.
2. Charge air system 229

1 - 8 Nm
❑ Fitting location
⇒ page 231
2 - Bracket
tion
3 - Charge air cooler
4 - Connecting hose
5 - 8 Nm
6 - To turbocharger.
7 - Connecting pipe
8 - To intake connecting pipe.
9 - Vacuum reservoir
10 - 15 Nm
11 - 8 Nm
12 - O-ring
13 - Charge air pressure send‐
er - G31- with intake air tem‐
perature sender - G42-
14 - 3 Nm
lkswage es n
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tho
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a ac
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un
pt
an
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itte
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erm
ab
ility
ot p
wit
is n
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ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
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Cop py
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pyri by
Vo
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by
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Prote AG.

1 - 8 Nm
Fitting location ⇒ page 231
2 - Bracket
tion
3 - Charge air cooler
❑ To remove, bring lock
carrier into service posi‐
tion ⇒ General body re‐
pairs, exterior; Rep. gr.
50 ; Body - front; Lock
carrier - service position
4 - Sealing strip
❑ Pushed onto top and
bottom of charge air
cooler
5 - 3 Nm
6 - Charge air pressure sender
- G31- with intake air tempera‐
ture sender - G42-
7 - O-ring
8 - Bracket
9 - 5 Nm
10 - Connecting hose
11 - Charge air pipe agen
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❑ To intake manifoldut
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❑ Assembly overview - in‐

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13 - 8 Nm
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Securing bolts for charge air cooler

rrectness of i
To loosen or tighten securing bolts -arrows- remove bumper cov‐

er.
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2.2 Hose connections
2.2.1 Installing hose connections with plug-in

connectors
Caution
The seal in the plug-in connector can be damaged if the se‐

curing clip is in the locked position when fitting the connector.
This can cause leakage. Observe installation instructions.
Removing
– Release plug-in connector by pulling out retaining clip
-arrow-. Separate hose/pipe without tools.
Installing
– If renewed, place oil seal in groove of charge air hose. Ensure
gen AG
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the seal is correctly seated in the groove. yV
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– Lubricate sealing surface and seal with oil.thoris nte
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– Bring retaining clip to release position -1-.
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– Bring securing clip to locking position -2- and then push charge
h re
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air hose again.
spec
es, in part or in w
– Check if plug-in connector seats correctly and is properly en‐
t to the co
gaged by pulling hose.
rrectness of i
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2.2.2 Hose connections with spring band ring
Note
There is a danger of a “hose detaching” whilst driving after re‐

moving and reinstalling charge pressure lines with spring-type
clips. For this reason, spring band rings are used which can be
opened if a defect item requires the charge pressure line has to
be disconnected. If it is necessary to remove the charge air pipe
during repair work, destroy the spring band ring using a suitable
tool (e.g. angle grinder) and renew with a replacement part ac‐
cording to ⇒ Electronic Parts Catalogue (ETKA) .
2.3 Checking charge wagair system for leaks

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♦ Charge air system
s a tester - V.A.G 1687-
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♦ Adapter - V.A.G 1687/10-

s o
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– Remove intake hose -1- from air filter.

form
mer
– Insert adapter - V.A.G 1687/10- in intake hose -1- and secure

atio
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with clip.
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Prepare charge air system tester - V.A.G 1687- as follows:

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– Turn pressure regulating valve -2- anti-clockwise onto stop.

– Close valves -3- and -4-.
Note
To turn the pressure control valve -2- the knob must be pulled
upwards.
– Connect charge air system tester - V.A.G 1687- to adapter -

V.A.G 1687/10- as shown.
AG. Volkswagen AG d
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– Connect compressed air hose -1- (compressed air source) to

charge air system tester - V.A.G 1687- .
Note
If there is water in the sight glass, drain at water drain screw

agen
-6-.
AG. Volkswagen AG
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– Open valve -3-. ris
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– Adjust pressure to 0.5 bar with pressure
ss
regulating valve -2-. au ac
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Caution itte
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The pressure must not exceed 0.5 bar! If the pressure is too
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high this can cause damage to the engine.
, is n
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spec
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– Open valve -4- and wait until the test circuit is filled. If neces‐
t to the co
sary readjust pressure to 0.5 bar.
– Check the charge air system for leaks by listening, touching,
rrectness of i
with leak detector spray or using ultrasonic tester - V.A.G
1842- .
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atio
♦ How to use the ultrasonic tester - V.A.G 1842- ⇒ operating
om
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instructions
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♦ If leaks occur, when doing any repair work observe notes for
sd
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charge air system ⇒ page 229 .

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♦ Depressurise test circuit by detaching coupling from adapter -

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AG. Volkswagen AG d
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23 – Mixture preparation - injection
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1 Injection system s
ce
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nl
pt
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The diesel direct injection system control unit is equipped with a
itte
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fault memory. Read fault memory before and after making repairs
ab
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or adjustments.
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⇒ “1.3 Removing and installing pre-wired wiring harness for unit
injectors and glow plugs”, page 237
rrectness of i
⇒ “1.4 Assembly overview - unit injector”, page 240
l purpos
⇒ “1.5 Removing and installing unit injector”, page 241

⇒ “1.6 Adjusting non-contact gap of unit injectors”, page 243
nform
ercia
⇒ “1.7 Removing and installing O-rings for unit injector”,

m
page 244
at
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1.1 Safety precautions
or
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ate
do
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WARNING
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sitions.
hot components.

rear seat and operated by a second person from this location.
♦ If test and measuring instruments are operated from front pas‐
senger seat and the vehicle is involved in an accident, there
is a possibility that the person sitting in this seat may receive
serious injuries when the airbag is triggered.
To prevent injuries to persons and/or destruction of the injection
and glow plug system, the following must be noted:
♦ The ignition must be switched off before connecting or dis‐
connecting injection or glow plug system wiring or tester ca‐
bles.
♦ If the engine is to be turned at starter speed, without starting,
e.g. when checking compressions, disconnect unit injector
connector on cylinder head.
♦ Before disconnecting battery, obtain radio code for radios with
anti-theft coding.
♦ Disconnecting and connecting the battery must be done only
with the ignition switched off because the control unit for diesel
direction injection system could otherwise be damaged.
236 Rep. gr.23 - Mixture preparation - injection

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When working on fuel supply ris and injection system, pay careful
ed
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attention to the following
aut rules for cleanliness:
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connecting. un
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lint-free cloths.
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tool boxes etc.).
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ss
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1.3 Removing and installing pre-wired wir‐
te
sd
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ing harness for unit injectors and glow
pr
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plugs
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Special tools and workshop equipment required rig ht
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♦ Puller - T10312- Prote
cted AG.
agen
♦ Special wrench - T10310-
1. Injection system 237

Removing
Caution
Removal and installation of the pre-wired wiring harness may

only be undertaken by unscrewing the clips. Releasing the ca‐
ble channel at the clips bends the clips which may break the
cables due the excessive play. This also applies when chang‐
ing the unit injectors and all work which does not require the
central connector to be completely removed.
Note
Disconnecting connectors on piezo unit injectors may enonly

AG. Vbe
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wagen AG
dertaken using special tool puller - T10312- .Volkswag does
not
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– Remove engine cover. ut
ho eo
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To do this, pull engine cover at front and right upwards abruptly
s
ce
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nl
-arrows A- and then pull forwards out of rear fastening
pt
du
an
-arrow B-.
itte
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ab
– Remove cylinder head cover ⇒ page 67 .
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– Disconnect central connector on cylinder head.
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spec
es, in part or in w
t to the co
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– Fit special wrench - T10310- on adapter ring and release it by
l purpos
turning key through 90° (1/4 turn) in -direction of arrow-.

nform
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– Pull the securing clip -1- upwards lightly with a screwdriver and
AG.
press the central connector -2- through inwards.

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– Slide the puller - T10312- onto the unit injector connector from
ce
le
the side and pull it off in -direction of arrow-. Use long-nosed
un
pt
an
d
pliers for the older connector version.
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t to the co
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– Pull connectors off glow plugs -1- Unscrew securing bolts -2-
of steel clips and remove complete pre-wired wiring harness.
nform
ercia
Installing
m
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com
tion in
r
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thi
note the following:
s
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– Route pre-wired wiring harness and tighten securing bolts to

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10 Nm.
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– Guide central connector through opening in retaining frame,

ensure securing clips -arrows- are seated correctly when do‐
ing this.
– Fit adapter ring (colour marked “longer” stud -arrow- faces 12

o'clock)

– Fit special wrench - T10310- on adapter ring and lock it by

turning key through 90° (1/4 turn) in opposite
-direction of arrow-.
Note
When adapter ring is installed correctly the colour marked “short‐

er” stud faces 12 o'clock.
– Fit central connector to cylinder head and lock in position.

– Install cylinder head cover ⇒ page 67 .
1.4 Assembly overview - unit injector

♦ ⇒ “1.2 Rules for cleanliness”, page 237
♦ Always renew seals and O-rings
1 - 20 Nm + turn (90°)
❑ Renew
2 - Rocker arm shaft
❑ With rocker arms
⇒ page 241
3 - Lock nut, 30 Nm
4 - Adjuster screw AG. Volkswagen AG d
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❑ Renew byV
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5 - Ball stud hor eo
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❑ Renew ss a c
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6 - Unit injector
pt
du
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itte
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⇒ page 241
ility
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7 - O-ring
h re
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spec
es, in part or in w
8 - O-ring
t to the co

9 - O-ring
rrectness of i

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10 - Heat shield seal

❑ Renew
nform
ercia
11 - Circlip
m
at
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ion
12 - Cylinder head
c
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or
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13 - Tensioning block
a
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or
14 - 12 Nm + turn (270°)
f
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t.
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❑ Renew
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1.5 Removing and installing unit injector

equipment required
♦ Universal dial gauge brack‐
et - VW 387-
♦ Socket XZN 10 - 3410-
♦ Special wrench, long reach
XZN 6 - T10054-
♦ Puller - T10055-
♦ Torque wrench -
V.A.G 1331-
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mer
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1.5.1 Removing
te
sd
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– Remove toothed belt guard upper part.

fo
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t.
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– Remove cylinder head cover. ⇒ page 67 t. Cop py
rig
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– Turn crankshaft until the cam pair point evenly upwards for the yri
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unit injector which is to be removed.
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Prote AG.
– Loosen lock nuts of adjustment screws -1- and remove ad‐
justment screws.
– Remove rocker arm securing bolts -2- (from outwards to in‐
wards) with socket driver XZN 10 - 3410- and remove rocker
arm shaft.
– Remove tensioning block securing bolt -3- with special wrench
- T10054- and remove the block.
– Lever connector off unit injector using a screwdriver. Support
opposite side of connector with light finger pressure to prevent
canting.
Observe unit injector cylinder allocation.

AG. Volkswagen AG d
agen oes
olksw not
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Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ised b ➤ , Touran 2003 ➤ ara
nte
r
4-cylinder diesel engine (1.9 l engine) - Edition
ut
ho 12.2013 eo
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s
– Insert puller - T10055- in place of the clamping block in the slot
ce
le
un
pt
on the side of the unit injector.
an
d
itte
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rm
ab
– Pull unit injector out of cylinder head seat by gently tapping
pe
ility
upwards.
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, is n
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es, in part or in w
t to the co
rrectness of i
l purpos
nform
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com
tion in
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1.5.2 Installing
en
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t.
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Note by c lksw
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♦ Each time work is performed which requires adjustment of the

unit injector, the adjustment screw in the rocker arm and also
the unit injector ball stud must be renewed.
♦ New unit injectors are supplied with O-rings and heat shield
seal.
– Heat shield seal and O-rings must be renewed if old unit in‐
jector is reused. ⇒ page 244
– Check that the 3 O-rings and the heat shield seal along with
securing clip are seated correctly before installing unit injector.
Note
The seals must not be twisted.
– Oil the seals and fit the unit injector into the seat in cylinder
head with great care.
– Push the unit injector evenly into the cylinder head onto its limit
stop.
– Insert tensioning block in slot on side of unit injector.
Note
If the unit injector is not at right angles to the tensioning block the
securing bolt may loosen and this can damage the unit injector or
the cylinder head.
– Therefore align the unit injector as follows.

– Screw new securing bolt into clamping block, but do not tighten
(it must still be possible to turn the unit injector slightly).
– Now align unit injector at right angles to camshaft bearing seat.

– Check dimension “a” from outer edge of cylinder head to roun‐

ded edge of unit injector with a vernier gauge (measuring
range at least 400 mm).
Cylinder Dimension “a”
1 333.0 ± 0.8 mm
2 245.0 ± 0.8 mm
3 153.6 ± 0.8 mm
4 65.6 ± 0.8 mm
– If necessary, adjust the unit injector and tighten the securing
bolt as follows:
– Tighten securing bolt to 12 Nm and turn 270° (3/4 turn) further
(turning further can be done in several stages).
– Fit rocker arm shaft and tighten new securing bolts as follows:
– First evenly tighten inner bolts -2- and then outer bolts -1-
hand-tight. Then using same sequence, tighten to 20 Nm and
90° (1/4 turn) further evenly.
– Adjust non-contact gap of unit injectors ⇒ page 243 .
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1.6 Adjusting non-contact gap of unit injec‐

ility
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spec
– Fit dial gauge onto adjustment screw of unit injector as shown.

t to the co
– Turn crankshaft in direction of engine rotation until roller of

rocker arm is located at tip of drive cam. Roller side
-arrow A- positioned at highest point, dial gauge -arrow B-
rrectne
positioned at lowest point.

– Remove dial gauge.
ss o
cial p
– Now turn the adjuster screw into rocker arm until significant
f in
resistance can be felt (unit injector is at limit stop).

form
mer
atio
om
n
c
i
or
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te
sd
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– Turn adjustment screw 180° back off stop.

um
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fo
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– Hold adjuster screw in this position and tighten lock nut to 30
yi Co
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– Connect unit injector connector.
co Vo
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– Install cylinder head cover ⇒ page 67 .

1.7 Removing and installing O-rings for unit

injector
♦ Assembly sleeves - T10056-
1.7.1 Removing
– Lever old O-rings very carefully out of unit injector.
– Above all ensure that burrs are not caused on O-ring seating.
1.7.2 Installing
Note
♦ Always use the assembly sleeves to fit the O-rings. There is a

danger of damaging the O-rings if the sleeves are not used.
♦ Gradual introduction of O-rings without different coloured
markings. Note the correct allocation of O-rings to grooves:
the thickness of the rings reduces towards injector nozzle.
♦ Prevent O-rings from rolling when sliding them on. The O-rings
AG. Volkswagen A
must not be twisted in their seats in unit injector.
olks
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– Pull heat shield seal off together withho securing clip. tee
aut or
ac
– Clean seating surfaces for O-rings on unit injector very care‐ ss
ce
le
fully.
un
pt
an
d
itte
– Place assembly sleeve - T10056/1- onto stop on unit injector.

y li
erm
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– Push the upper, thicker O-ring carefully onto assembly sleeve

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and into seat on unit injector.

is n
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ole,
– Remove assembly sleeve.

spec
t to the co
rrectness o
cial p
f inform
mer
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c
i
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Cop py
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co
244
by lksw
cted agen
Rep. gr.23 - Mixture preparation - injection Prote AG.

– Slide the middle, thinner O-ring carefully onto assembly sleeve
and into seat on unit injector.

– Push the lower O-ring carefully onto the assembly sleeve and
into the seat of the unit injector.
– Fit new heat shield seal together with securing clip.
en AG. V
olkswagen AG
ag does
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mer
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2 Air filter
⇒ “2.1 Assembly overview - air filter”, page 246
2.1 Assembly overview - air filter
1 - Intake hose
2 - Air mass meter - G70-
3 - O-ring
4 - 8 Nm
5 - Upper part of air filter
6 - 8 Nm AG. Volkswagen AG d
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lksw not
7 - Vacuum hose by
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❑ To solenoid valve block ho ris nte
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8 - Filter element ss c
ce
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un
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9 - Air duct
an
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❑ To lock carrier.
rm
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pe
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10 - Lower part of air filter
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11 - 10 Nm
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
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tion in
r
te o
thi
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t.
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Cop py
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3 Intake manifold
⇒ “3.1 Assembly overview - intake manifold”, page 247
⇒ “3.1.4 Cleaning the intake manifold flap support, Engine code
BLS and BXJ”, page 250
3.1 Assembly overview - intake manifold

⇒ “3.1.1 Engine codes AVQ, BKC, BRU, BXE and BXF”,
page 247
⇒ “3.1.2 Engine code BJB”, page 248
3.1.1 Engine codes AVQ, BKC, BRU, BXE and BXF
1 - Intake manifold
❑ Tighten securing bolts agen
AG. Volkswagen AG d
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to 22 Nm. Volksw not
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2 - O-ring horis nte
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❑ Renew ss a ra
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3 - Intake connecting pipe

nl
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❑ With exhaust gas recir‐
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culation valve
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4 - 10 Nm
, is n
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hole
5 - Intake manifold flap motor -
spec
V157-
es, in part or in w
t to the co
❑ The intake manifold flap
is closed for approx. 3
seconds when stopping
engine and then opens rrectness of i
again. This reduces the
l purpos
stop jolt.
6 - 10 Nm
nf
ercia
orm
7 - Connecting pipe
m
atio
m
❑ To exhaust gas recircu‐

o
n in
or c
lation cooler
thi
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8 - 22 Nm
o
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9 - Seal
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❑ Renew C py
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3. Intake manifold 247

3.1.2 Engine code BJB
1 - Intake manifold
❑ Tighten securing bolts
to 22 Nm.
2 - O-ring
❑ Renew
3 - Intake connecting pipe
culation valve and in‐
take manifold flap
4 - 10 Nm
5 - Seal
❑ Renew
6 - Connecting pipe
❑ To exhaust gas recircu‐
lation cooler
7 - 10 Nm
8 - Bracket
AG. Volkswagen AG d
9 - Vacuum actuator ksw
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not
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10 - To solenoid valve
ise
d b block ara
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11 - 22 Nm s a ut ra
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1 - Seal
❑ Renew
2 - Intake manifold
to 22 Nm
❑ Remove turbocharger
⇒ page 224 to remove
3 - Seal AG. Volkswagen AG d
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❑ Renew olksw not
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4 - Connection horis nte
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5 - Intake manifold flap motor - ss c
V157-
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❑ The intake manifold flap
itte
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is closed for approx. 3
rm
ab
pe
ility
seconds when stopping
ot
wit
engine and then opens
, is n
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again. This reduces the
hole
stop jolt.
spec
es, in part or in w
t to the co
6 - From charge air cooler
7 - 10 Nm
rrectness of i
valve - N18- with exhaust gas
l purpos
recirculation potentiometer -
G212-
nform
ercia
❑ Before installing, check

sealing surface on in‐
m
a
com
t
take manifold for soiling
ion in
and clean if necessary
r
te o
thi
❑ If the exhaust gas recir‐
s
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do
culation valve - N18-
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with exhaust gas recir‐
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culation potentiometer -
yi Co
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G212- is renewed the
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ignition must be switch‐
ht
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ed off and then on again. Then wait one minute for the control unit to run down (valve learns, main relay
by c lksw
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must click) Prote AG.
❑ Start engine and run at idling speed for one minute.

❑ Then read engine control unit fault memory. No fault must be stored in the memory.
❑ If a fault is stored in the fault memory, erase fault memory and repeat work sequence
❑ Assembly overview - exhaust gas recirculation ⇒ page 279
9 - Seal
❑ Renew
❑ For exhaust gas recirculation cooler
❑ Assembly overview - parts of exhaust gas recirculation
⇒ page 276
11 - 22 Nm
12 - Bracket
13 - 22 Nm
3. Intake manifold 249

3.1.4 Cleaning the intake manifold flap sup‐

port, Engine code BLS and BXJ
Note
Carbon deposits can occur in the throttle valve support through

the combination of unfavourable factors. AG. Volkswagen AG d e.g.
swagenIf these are found, oes
when disassembling the exhaust by gas recirculation valve - N18- or guar
Vol
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the intake manifold flap motor
ris
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tee
be cleaned. utho or
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itte
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Acetone is highly inflammable. Please observe the accidental
ot p
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regulations and safety notes when handling with highly inflam‐
, is n
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mable fluids. Wear eye protection and protective clothing to
hole
avoid possible injury and skin contact.
spec
es, in part or in w
t to the co
– Remove intake manifold flap connection.
rrectness of i
– Remove the exhaust gas recirculation valve - N18- and the
intake manifold flap motor - V157- .
l purpos
– Thoroughly clean intake manifold flap support, especially

around exhaust gas return valve, using commercially available
nform
ercia
acetone according to DIN 53247 and cleaning brush.

m
at
– Wipe off intake manifold flap support using a lint-free cloth.
om
ion
c
in t
r
– Allow the acetone to evaporate fully, assemble the cleaned

o
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intake manifold flap support, replace the seals and insert it

a
do
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back in position.
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4 Engine control unit

⇒ “4.1 Reading and deleting engine control unit event memory”,
page 251
⇒ “4.2 Adapting functions and components”, page 252
⇒ “4.3 Removing and installing engine control unit (Golf)”,
page 253
⇒ “4.4 Removing and installing anti-theft engine control unit
(Golf)”, page 253
⇒ “4.5 Removing and installing engine control unit (Golf Plus)”,
page 256
⇒ “4.6 Removing and installing anti-theft engine control unit (Golf
Plus)”, page 256
⇒ “4.7 Removing and installing engine control unit (Touran)”,
page 258
⇒ “4.8 Removing and installing anti-theft engine control unit (Tour‐
an)”, page 259
⇒ “4.9 Engine control unit (Passat)”,
wage
n AG. Vopage 261 does
lkswagen AG
olks not
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4.1 Reading
oris
ed
b
and deleting engine control
ara
ntunit
ee
event
sa
uth
memory or
ac
s
ce
e

nl
pt
du
an
itte
♦ Vehicle diagnostic, testing and information system - VAS

y li
erm
ab
5051-
ility
ot p
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
– Connect vehicle diagnostic, testing and information system -

m
at
om
VAS 5051- as follows:

on
c
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or
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4. Engine control unit 251

– Push diagnostic cable connector onto diagnostic connector.

Only when engine does not start:
Select operating mode . Volkswagen AG
gen AG does
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– Press button on display for “Vehicle self-diagnosis”. y Volk not
gu
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Select vehicle system horis
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– Press “01 - Engine electronics” button on display.
ss c
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un
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The control unit identification and engine control unit coding are
an
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itte
indicated on display.
y li
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Select diagnostic function
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– Press button “02 - Read fault memory” on display.
h re
ole,
spec
– If no fault is stored in engine control unit “0 fault detected” is
displayed.
t to the co
– If faults are stored in the engine control unit, these are shown
one below the other on the display.
rrectne
– Press ← button.
ss
– Press button “05 - Clear fault memory” on display.
o
cial p
f in
– Press function “06-End output”.
form
mer
atio
m
4.2 Adapting functions and components

o
n
c
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♦ Vehicle diagnostic, testing and information system - VAS

fo
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Select “Guided fault finding” in Vehicle diagnostic, testing and in‐

formation system - VAS 5051- .
When all control units have been read:
– Press “GoTo” button.
– Select “Function/component selection”.
– Select “Drive train”.
– Select “Engine code”.
– Select “01 Systems capable of self-diagnosis”.
– Select “Engine management”.
– Select “Functions”.
– Select “Function or component”.

4.3 Removing and installing engine control

unit (Golf)
– Before the engine control unit is removed, the control unit
identification must be read and, thus, the coding of the current
control unit as well ⇒ page 252 .
Removing
– Switch off ignition. olkswage es n
ot g
V
by ua
– Remove wiper ris
edarms, plenum chamber cover and plenum
ran bulk‐
tee
head ⇒ Electrical
utho system; Rep. gr. 92 ; Windscreen wiperor
system;ssRemoving and installing windscreen wiper systemac.
a
ce
e
nl
– Bend catch open slightly -1-.
pt
du
an
itte
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– Then push engine control unit out of retainer -arrow-.
erm
ab
ility
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– Release now connector from engine control unit, disconnect
wit
, is n
connector.
h re
hole
spec
Installing
es, in part or in w
t to the co
– Fit connector to engine control unit and lock connector in po‐
sition.
– Push engine control unit onto bracket.
rrectness of i
l purpos
nform
– Press catch -1- against engine control unit.
mercia
– Install plenum chamber bulkhead, plenum chamber cover and

at
om
io
wiper arms ⇒ Electrical system; Rep. gr. 92 ; Windscreen

n
c
in t
wiper system; Removing and installing windscreen wiper sys‐

or
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tem .
at
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Prote AG.
4.4 Removing and installing anti-theft en‐

gine control unit (Golf)
Removing and installing anti-theft engine control unit Golf Plus
⇒ page 256 .
♦ Electric cutter - V.A.G 1561 A-
♦ Saw set - V.A.G 1561/14-

♦ Grip pliers
AG. Volkswagen AG d
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♦ If the engine control unit is to be renewed,
ss a
connect Vehicle c
diagnostic, testing and information system - VAS 5051B- and
ce
le
un
pt
carry out “Renewing engine control unit” in guided functions.
an
d
itte
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rm
♦ The shear-head bolt threads are coated with locking com‐
ab
pe
ility
pound. To simplify removing, the shear-head bolts can be
ot
wit
heated using hot air blower - VAS 1978/14- . When doing this,
, is n
h re
ensure that no adjacent cables, connectors or components are
hole
spec
damaged!
es, in part or in w
t to the co
Removing
rrectness of i
– Remove wiper arms, plenum chamber cover and plenum bulk‐
l purpos
head ⇒ Electrical system; Rep. gr. 92 ; Windscreen wiper

system; Removing and installing windscreen wiper system .
nform
ercia
– Cut into heads of shear-head bolts so that 2 parallel surfaces

are created -arrows-.
m
a
com
– Remove bolts with grip pliers . tion in

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by
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Prote AG.
– Insert a screwdriver between protective housing -A- and

bracket -arrow-.

– Lever up protective housing using screwdriver -A- and pull to

side off bracket -arrow-.
– Bend catch open slightly -1-.

– Then push engine control unit out of retainer -arrow-.
– Release now connector from engine control unit, disconnect
connector.
Installing
– Fit connector to engine control unit and lock connector in po‐
sition.
– Push engine control unit onto bracket.
– Press catch -1- against engine control unit.

– Push protective housing onto bracket.
lkswage es n
o ot g
byV ua
d ran
ir se tee
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erm
– Tighten new shear-head bolts -1- evenly until heads shear off.
ab
ility
ot p
– Install plenum chamber bulkhead, plenum chamber cover and

wit
, is n
wiper arms ⇒ Electrical system; Rep. gr. 92 ; Windscreen

h re
hole
wiper system; Removing and installing windscreen wiper sys‐

spec
tem .
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
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Prote AG.


unit (Golf Plus)
Note
If the engine control unit is to be renewed, connect Vehicle diag‐

nostic, testing and information system - VAS 5051B- and carry
out “Renewing engine control unit” in guided functions.
Removing:
– Remove plenum chamber bulkhead ⇒ General body repairs;
Rep. gr. 50 ; Body - front; Plenum chamber bulkhead .
– Loosen securing nuts -arrows-.
nector.
AG. Volkswagen AG d
agen oes
o lksw not
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– Push bracket -1- off engine control dunit
by
in direction of arrow. ara
rise nte
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Installing: auth
ra
ss c
– Push bracket onto engine control unit.
ce
le
un
pt
an
d
itte
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erm
ab
ility
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is n
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ole,
spec
t to the co
rrectne
– Tighten securing nuts -arrows- to 10 Nm.

– Fit connectors and lock in position.
ss o
– Install plenum chamber bulkhead ⇒ General body repairs;

cial p
f in

form
mer
atio
om
n
c
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Prote AG.
gine control unit (Golf Plus)
♦ Grip pliers

Note
♦ If the engine control unit is to be renewed, connect Vehicle

diagnostic, testing and information system - VAS 5051B- and
carry out “Renewing engine control unit” in guided functions.
♦ The shear-head bolt threads are coated with locking com‐
pound. To simplify removing, the shear-head bolts can be
heated using hot air blower - VAS 1978/14- . When doing this,
ensure that no adjacent cables, connectors or components are
damaged!
Removing
– Twist shear-head bolts -arrows- out using grip pliers and re‐
move cover from protective housing.
– Then remove securing nuts for control unit bracket -arrows-.
wage e
– Release connector
Vol from engine control unit, disconnect
ks s no
t gu con‐
by
nector. ised ara
nt
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ho
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ac
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rm
ab
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, is n
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hole
spec
es, in part or in w
t to the co
– Press catches -1- and -2- outwards. Then pull engine control
rrectness of i
unit off control unit bracket in direction of arrow.

l purpos
Installing
– Push engine control unit onto control unit bracket until it en‐
nform
ercia
gages in catches.
m
– Fit connectors to engine control unit and lock in position.

com
tion in
r
te o
thi
s
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fo
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by
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Prote AG.

– Tighten securing bolts -arrows- to 10 Nm.

– Install cover of protective housing.
– Tighten new shear-head bolts -arrows- evenly until heads

shear off.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
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nl
pt
du
an
itte
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erm
ab
ility
ot p
unit (Touran) wit

, is n
h re
hole
– Before removing engine control unit, read control unit identifi‐

spec
cation and, thus, coding of current control unit as well

es, in part or in w
⇒ page 252 .
t to the co
4.7.1 Removing
rrectness of i

l purpos
– Remove plenum chamber bulkhead. ⇒ General body repairs;

Rep. gr. 50 ; Body - front, plenum chamber bulkhead .
nform
ercia
– Loosen securing nuts -arrows-.

m
at
om

ion
c
nector.
in t
or
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ate
do
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for
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Prote AG.

– Push bracket -1- off engine control unit in direction of arrow.
4.7.2 Installing
– Push bracket onto engine control unit.
– Tighten securing nuts -arrows- to 10 Nm.
– Fit connectors and lock in position.
– Check previous coding and adapt coding of the new control
unit ⇒ page 252 .
– Read fault memory of new engine control unit and erase fault
memory if necessary. ⇒ page 251
AG. Volkswagen AG d
agen
– Carry out a road test. Volksw
oes
not
by gu
d ara
– Read control unit fault memory again.orise nte
eo
th
au ra
ss c
ce
le
un
pt
an
d

itte
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erm
ab
gine control unit (Touran)
ility
ot p
wit
is n
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ole,
spec
♦ Grip pliers
t to the co
♦ Hot air blower from wiring harness repair set - VAS 1978-
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
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te
sd
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pr
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fo
en
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t.
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Cop py
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Note
ht
pyri by
Vo
co lksw
by
cted agen
Prote
If the engine control unit is to be renewed, connect Vehicle diag‐
AG.
nostic, testing and information system - VAS 5051B- and carry

out “Renewing engine control unit” in guided functions.
Removing

Note
The shear-head bolt threads are coated with locking compound.

Heating the shear-head bolt with a hot air blower releases the
locking effect of the locking compound.
Caution
Cover lines, connections and control units in the vicinity of the

engine control unit to prevent damage through heat.
Perform settings on hot air blower -4- as shown:

– Turn temperature setting potentiometer -2- to maximum heat
output (600 °C).
– Set two-stage switch for volume of air -3- to position 3.
WARNING
When shear-head bolts are heated up, parts of the protective

housing will be subjected to a large amount of heat. Wear pro‐
tective gloves to avoid possible injury.
– Place nozzle of hot air blower close to shear-head bolt.

– Switch on hot air blower and heat the bolts.
– Unscrew shear-head bolts -arrows- out using pliers and re‐

move cover from protective housing. AG. Volkswagen A gen G do
swa es n
– Then remove securing nuts for control unitbybracket
Vol
k
-arrows-. ot g
ua
ed ran
oris tee
th or
au ac
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nl
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itte
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erm
ab
ility
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, is n
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hole
spec
es, in part or in w

t to the co
nector.
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
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o
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Prote AG.

– Press catches -1- and -2- outwards. Then pull engine control
unit off control unit bracket -in direction of arrow-.
Installing
– Push engine control unit onto control unit bracket until it en‐
gages in catches.
– Fit connectors to engine control unit and lock in position.
– Tighten securing bolts -arrows- to 10 Nm.

– Install cover of protective housing.
AG. Volkswagen AG d
agen oes
olksw not
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d by ara
ise nte
or eo
h
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ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
– Tighten new shear-head bolts -arrows- evenly until heads
ility
ot p
shear off.
wit
, is n
h re
– Install plenum chamber bulkhead ⇒ General body repairs;
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
4.9 Engine control unit (Passat)

on
c
in t
or
his
e
⇒ “4.9.1 Removing and installing engine control unit”, page 261

at
do
priv
cum
⇒ “4.9.2 Removing and installing anti-theft engine control unit”,

for
en
g
page 263
n
t.
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4.9.1 Removing and installing engine control

t. rig
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unit
by c lksw
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Prote AG.
If the engine control unit is to be renewed, connect vehicle diag‐

nosis, testing and information system - VAS 5051B- and perform
guided functions “Renewing control unit”.
DANGER!
For vehicles with heavy duty running gear; vehicle must be re‐
stricted to a maximum of 210 km/h via the engine control unit.
Drive shafts can be damaged at speeds above 210 km/h. Per‐
form function “Restricting maximum speed” in guided functions
using vehicle diagnostic, testing and information system - VAS
5051B- .

Removing
– Remove plenum chamber cover ⇒ Rep. gr. 64 .
– Pull connector -1- off heated windscreen control unit - J505- .
– Slide connector locking devices -2- on engine control unit out‐
wards and pull off both connectors.
– Remove securing bolts -3-.
– Remove retainer frame with engine control unit from plenum
chamber.
– Press locking device -1- outwards and slide engine control unit
-2- in -direction of arrow-.
Installing
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
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un
pt
an
d
itte
– Slide engine control unit -1- into retaining frame in

y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
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o
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fo
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ng
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co lksw
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cted agen
Prote AG.

– Fit retainer frame with engine control unit onto retainer -4-.
Specified torque of securing nuts for retainer -4-: 6 Nm.
– Tighten securing bolts -3- to 7 Nm.
– Fit connectors to engine control unit and slide locking devices
-2- inwards.
-
– Fit connector -1- to heated windscreen control unit - J505- .
– Install plenum chamber cover: ⇒ General body repairs, exte‐
rior; Rep. gr. 50 ; Bulkhead; Removing and installing plenum
chamber cover .
– Install wiper arms ⇒ Electrical system; Rep. gr. 92 ; Wind‐
4.9.2 Removing and installing anti-theft en‐

gine control unit
♦ Hot air blower from wiring harness repair set - VAS 1978-
wage e
♦ Nozzle attachment from wiring harness yV
olks
repair set - VAS 1978- s not gu
b ara
ed
If the engine control unit is to tbe
ho renewed, connect vehicle diag‐
ris nte
eo
nosis, testing and informations a system - VAS 5051B- and perform
u ra
c
guided functions “Renewing control unit”.
s
ce
le
un
pt
an
d
itte
y li
DANGER!
rm
ab
pe
ility
ot
For vehicles with heavy duty running gear; vehicle must be re‐
wit
, is n
stricted to a maximum of 210 km/h via the engine control unit.

h re
hole
Drive shafts can be damaged at speeds above 210 km/h. Per‐

spec
form function “Restricting maximum speed” in guided functions

es, in part or in w
t to the co
using vehicle diagnostic, testing and information system - VAS

5051B- .
rrectness of i
Removing
l purpos

nform
ercia

m
a
com
tion in
– Remove plenum chamber cover ⇒ Rep. gr. 64 .

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Note
The shear-head bolt threads are coated with locking compound.

Heating the shear-head bolt with a hot air blower releases the
locking effect of the locking compound.
Caution
Cover lines, connections and control units in the vicinity of the

engine control unit to prevent damage through heat.
Perform settings on hot air blower -4- as shown:

– Turn temperature setting potentiometer -2- to maximum heat
output (600 °C).
– Set two-stage switch for volume of air -3- to position 3.
WARNING
When shear-head bolts are heated up, parts of the protective

housing will be subjected to a large amount of heat. Wear pro‐
tective gloves to avoid possible injury.
– Place nozzle of hot air blower close to shear-head bolt.

– Switch on hot air blower and heat bolt for about 20 to 25 sec‐
AG. Volkswagen AG d
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– Unscrew tshear-head
ho
ris
bolt -2- using pliers on bolt head. tee
or
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The procedure
ss for the second shear-head bolt is exactly the c
ce
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same.
nl
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– Pull connector -1- off heated windscreen control unit - J505- .

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– Lift cover -1- and pull it forwards.

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– Slide connector locking devices -1- on engine control unit out‐

wards and pull off both connectors.
– Remove retainer frame with engine control unit from plenum
chamber.
– Press locking device -1- outwards and slide engine control unit
-2- in -direction of arrow-.
Installing AG. Volkswagen AG d
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– Slide engine control unit -1- into retaining frame in
es, in part or in w
t to the co
– Fit retainer frame with engine control unit onto retainer in ple‐
num chamber.
rrectness of i
Specified torque of securing nuts for retainer: 6 Nm.
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– Fit connectors to engine control unit and slide locking devices

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– Slide cover -1- over engine control unit and press it down‐
wards.
– Tighten new shear-head bolts -2- evenly until bolt head shears
off.
– Fit connector -1- to heated windscreen control unit - J505- .
– Install plenum chamber cover ⇒ Rep. gr. 64 .
– Install wiper arms ⇒ Electrical system; Rep. gr. 92 ; Wind‐ n AG. Volkswagen AG do
screen wiper system; Removing and installing wiper armsol.kswage es n
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26 – Exhaust system
1 Exhaust system
⇒ “1.1 Assembly overview - front exhaust pipe with catalytic con‐
verter ”, page 267
⇒ “1.2 Assembly overview - silencer with mountings (vehicles with
front wheel drive)”, page 268
⇒ “1.4 Assembly overview - silencer with mountings (vehicles with
four-wheel drive)”, page 271
⇒ “1.3 Assembly overview - silencers (Passat)”, page 270
1.1 Assembly overview - front exhaust pipe with catalytic converter
1 - Front exhaust pipe with cat‐

alytic converter
2 - 40 Nm AG. Volkswagen AG d
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4 - Marking ut
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❑ For clamp. ss c ce
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❑ Installation position of
pt
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clamp ⇒ page 268 .

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5 - To front silencer
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6 - 25 Nm
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spec
7 - Mounting
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8 - 7 Nm
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9 - Seal
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10 - Clamp
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1. Exhaust system 267

Installation position of clamp

Position clamp at distance -a- = 5 mm from marking on front ex‐
haust pipe.
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1.2 Assembly overview - silencer with mountings (vehicles with front wheel ir se
d b ua
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drive) tho
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1 - 25 Nm
itte
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3 - Separating point
t to the co
❑ Marked by indentation
on exhaust tailpipe
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❑ During production, front
and rear silencers are
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installed as a single
component. For repairs,
front and rear silencers
nf
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are supplied separately.
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❑ The connection is made
om
with a clamp.
n in
or c
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❑ Separating exhaust tail‐

t
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pipe ⇒ page 269

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⇒ page 269 . yri
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❑ Evenly tighten threaded cted agen
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connections of clamping
sleeve (repair double
clamp)
❑ Specified torques for
clamp (repair double
clamp): M8 = 25 Nm,
M10 = 40 Nm
❑ Before tightening, align
cold exhaust system
free of tension
⇒ page 272
4 - Rear silencer
5 - Mounting
268 Rep. gr.26 - Exhaust system

6 - 25 Nm
7 - Tunnel bridge
8 - Front silencer
9 - Mounting AG. Volkswagen AG d
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Installation position of rear clamp (repair double clamp) s
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– Install clamp so that ends of bolts do not protrude beyond bot‐
an
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• Bolt connection faces to left.
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1.2.1 Separating front and rear silencers
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♦ Pneumatic sabre saw - V.A.G 1523 A-

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♦ Eye protection
Procedure
WARNING
Wear eye protection.
– Cut exhaust tailpipe at right angles at separating point

-arrow 2-.
– When installing, position repair double clamp -4- at side mark‐
ings -arrow 1- and -arrow 3-.

– Install repair double clamp so that end of bolt does not extend
beyond lower edge of clamp.
• Bolted connection faces rear.
– Align cold exhaust system free of tension ⇒ page 272 .
– Tighten bolts on repair double clamp. agen
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Specified torque, M10: 40 Nm aut
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1.3 Assembly overview - silencers (Passat)
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spec
1 - From front exhaust pipe
es, in part or in w
t to the co
2 - Clamp
❑ Before tightening, align
cold exhaust system
rrectness of i
free of tension
⇒ page 272
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❑ Tighten bolted connec‐

tions evenly.
nform
ercia
❑ Specified torque: M8 =
m
a
25 Nm, M10 = 40 Nm.
com
tion in
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3 - Front silencer
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6 - Separating point Prote AG.
❑ Marked by impressions
on exhaust pipe.
❑ During production, front
and rear silencers are
installed as a single
component. In event of
repair, front and rear si‐
lencers are supplied in‐
dividually and with a
clamping sleeve for pur‐
poses of connection
❑ Cut through exhaust
pipe at right angles at
separating point
-arrow A- using e.g.
body saw - V.A.G 1523-
(wear eye protection)
❑ During installation, posi‐
tion repair double clamp at side markings -arrows B-
❑ Evenly tighten threaded connections of clamping sleeve (repair double clamp)
❑ Specified torques for clamp (repair double clamp): M8 = 25 Nm, M10 = 40 Nm.
❑ Before tightening, align cold exhaust system free of tension ⇒ page 272
7 - Retaining ring

8 - Rear silencer
1.4 Assembly overview - silencer with mountings (vehicles with four-wheel

drive)
1 - From particulate filter

2 - Clamp
❑ Align exhaust system
free of stress before
tightening clamp
⇒ page 272 .
❑ Installation position
⇒ page 271
❑ Tighten bolted connec‐
tions evenly.
3 - Bracket
❑ For retaining ring
4 - 25 Nm
5 - Retaining ring
6 - Rear silencer
7 - Mounting
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Installation position of clamp

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– Install clamp so that ends of bolts do not protrude beyond bot‐

form
mer
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1.5 Aligning exhaust system free of stress

Prerequisite
• Engine must be cold.
Procedure
– Loosen bolted connection of clamp between front exhaust
pipe and silencer.
– Position clamp at distance -a- = 5 mm from marking on front
exhaust pipe and lightly tighten front bolted connection.
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– Push exhaust tailpipe with silencer forwards into clamp until by Vol ot g
ua
dimension -a- 15…17 mm is attained between mounting at‐rised ran
tee
tachment points for body and rear silencer. 17 mm. -Arrow-
autho
or
ac
points in direction of travel. ss
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– Align rear silencer horizontally.
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– With parts in this position, tighten bolted connections of clamp.
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Specified torque, M8: 25 Nm
ot
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Specified torque, M10: 40 Nm
hole
spec
es, in part or in w
– Once clamp has been tightened, check distance -a- and cor‐
t to the co
rect if necessary.
rrectness of i
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2 Emission control
⇒ “2.1 Assembly overview - front exhaust pipe with particulate
filter”, page 273
2.1 Assembly overview - front exhaust pipe

with particulate filter
Note
If the particulate filter or the exhaust gas pressure sensor 1 -

G450- is changed, the exhaust gas pressure sensor 1 - G450-
must always be adapted using diagnostic tester : Guided
functions; adapting exhaust pressure sensor 1 - G450- .

♦ Lambda probe open ring spanner set - 3337-
♦ Tool set - T10395-

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Note
rrectne
If the particulate filter or the exhaust gas pressure sensor 1 -

ss
G450- is changed, the exhaust gas pressure sensor 1 - G450-

o
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must always be adapted using diagnostic tester : Guided

inform
functions; adapting exhaust pressure sensor 1 - G450- .

mer
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2. Emission control 273

1 - 8 Nm
2 - Exhaust gas pressure sen‐
sor 1 - G450-
3 - Bracket
❑ For control lines
4 - 10 Nm
5 - Control line, 45 Nm
6 - Lambda probe - G39- , 50
Nm
❑ Grease only thread with
high-temperature paste
- G 052 112 A3- ; high-
temperature paste - G
052 112 A3- must not
get into the slots of
probe body
❑ To remove use Lambda
probe open ring span‐
ner set - 3337- .
7 - Exhaust gas temperature
sender bank 2 - G448- , 45 Nm
❑ Lubricate thread of
sender using high-tem‐ agen
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8 - Particulate filter aut ra
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❑ is removed downwards
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with exhaust gas pres‐
pt
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❑ To remove, remove
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⇒ Running gear, axles,

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steering; Rep. gr. 40 .

spec
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9 - Front exhaust pipe t to the co
10 - Marking
❑ For clamp.
rrectness of i
❑ Installation position of clamp ⇒ page 275 .

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11 - To front silencer
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12 - 25 Nm
m
13 - Mounting
at
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c
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14 - Temperature sender after particulate filter - G527-

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❑ 45 Nm
um
for
en
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❑ Lubricate thread of sender using high-temperature paste - G 052 112 A3-

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16 - Clamp, 7 Nm
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17 - Seal
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18 - 40 Nm
19 - Bracket
❑ Bolted to cylinder head.
Installation position of clamp AG. Volkswagen AG d

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– Position double clamp -a- = 5 mm fromsemarking
db on front ex‐ ara
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haust pipe of particulate filter. thori
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2. Emission control 275

3 Exhaust gas recirculation
Caution

tions:
♦ Route all the various lines and electrical wiring so that they
are in their original positions.
♦ e.g. for fuel, hydraulics, activated charcoal filter system,
coolant and refrigerant, brake fluid, vacuum.
hot components.
⇒ “3.1 Assembly overview - parts of exhaust gas recirculation”,

page 276
⇒ “3.2 Checking mechanical exhaust gas recirculation valve”,
page 280
3.1 Assembly overview - parts of exhaust

gas recirculation
olksw
⇒ “3.1.1 Engine codes AVQ, BKC, BRU,sBXE agenand BXF”,
AG. V agen AG
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page 276 by Vol not
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⇒ “3.1.2 Engine code BJB”, page
tho 278
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⇒ “3.1.3 Engine codes BLSssand BXJ”, page 279
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⇒ “3.2 Checking mechanical exhaust gas recirculation valve”,

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page 280
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3.1.1 Engine codes AVQ, BKC, BRU, BXE

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and BXF
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spec
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t to the co
Note
♦ The exhaust gas recirculation system is activated by the diesel

rrectness of i
direct injection system control unit - J248- via exhaust gas re‐
l purpos
circulation valve - N18- (electric-pneumatic) to the exhaust gas

recirculation valve (mechanical).
nform
ercia
♦ The electro-pneumatic exhaust gas recirculation valve - N18-

is located in the solenoid valve block.
m
at
om
io
♦ The cone-shaped plunger in the mechanical exhaust gas re‐

n
c
in t
r
circulation valve ensures that various cross sectional openings

o
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are possible at different plunger lifts.

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♦ Pulsed control enables every conceivable valve position.

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1 - 22 Nm
2 - Intake manifold
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❑ Tighten securing bolts uthor eo
to 22 Nm. ss a ra
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3 - Seal
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❑ Renew
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4 - Connecting pipe ot p
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5 - Cooler
h re
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spec
❑ For exhaust gas recircu‐
es, in part or in w
lation
t to the co
6 - 10 Nm
rrectness of i
8 - Connecting pipe
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Tightening sequence:
nf
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❑ 1. Attach to bypass flap
orm
m
❑ 2. Attach to manifold
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❑ 3. Tighten to bypass flap
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❑ 4. Tighten to manifold
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9 - Bypass flap
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❑ When activated, directs
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culation valve - N18- .
10 - Bracket
❑ For bypass flap
11 - 5 Nm
Connector assignment on solenoid valve block, engine codes

BKC, BRU, BXE and BXF
1- Vacuum connection (on non-return valve for brake servo)
2- Exhaust gas recirculation valve
3- Bypass flap
4- Air filter
5- Vacuum reservoir
6- Vacuum unit on turbocharger
3. Exhaust gas recirculation 277

3.1.2 Engine code BJB
Note

direct injection system control unit - J248- via exhaust gas re‐
circulation valve - N18- (electric-pneumatic) to the exhaust gas
recirculation valve (mechanical).
♦ The electro-pneumatic exhaust gas recirculation valve - N18-
is located in the solenoid valve block.
♦ The cone-shaped plunger in the mechanical exhaust gas re‐
circulation valve ensures that various cross sectional openings
are possible at different plunger lifts.
♦ Pulsed control enables every conceivable valve position.
1 - Intake manifold
culation valve and in‐
take manifold flap
to 22 Nm.
2 - From charge air cooler AG. Volkswagen AG d
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6 - Connecting pipe
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Pin assignment on solenoid valve block for engine code BJB

1- Vacuum connection (on non-return valve for brake servo)
2- Exhaust gas recirculation valve
3- Intake manifold flap
4- Air filter
5- Vacuum reservoir
6- Vacuum unit on turbocharger
Note

direct injection system control unit - J248- via the exhaust gas
recirculation potentiometer - G212- .
1 - Coolant hose
❑ To connection
2 - Seal
❑ Renew
3 - 22 Nm
4 - Connecting pipe agen AG. Volkswagen AG do
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5 - From exhaust
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6 - 25 Nm tho or
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7 - To connection for exhaust

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gas recirculation valve - N18-

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potentiometer - G212-
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❑ Assembly overview - in‐

hole
take manifold
spec
⇒ page 249
es, in part or in w
t to the co

cooler
rrectness of i
9 - 10 Nm
l purpos
10 - Coolant hose
❑ From rear coolant pipe
nf
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cooler changeover valve -

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14 - Vacuum actuator
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3. Exhaust gas recirculation 279

❑ Renew only together
with exhaust gas recirculation cooler
3.2 Checking mechanical exhaust gas recir‐

culation valve
♦ Hand vacuum pump with accessories - V.A.G 1390-
Test procedure
– Pull vacuum hose off exhaust gas recirculation valve.
to valve.
– Operate hand vacuum pump a few times.
– Pull hand vacuum pump hose off exhaust gas recirculation
valve. The diaphragm rod must audibly return to its original
position.
AG. Volkswagen AG d
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28 – Glow plug system

1 Glow plug system
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⇒ “1.1 Removing, installing and checking glow plugs”, lkswagen oes
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page 281 db
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⇒ “1.2 Characteristics of ceramic glow plugs”,
ut page 282
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⇒ “1.3 Removing, installing and checking sceramic glow plugs”,
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page 282
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⇒ “1.4 Removing and installing engine speed sender G28 ”, page erm
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284
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1.1 Removing, installing and checking glow
h re
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plugs
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♦ Jointed spanner - 3220- p by
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Test requirements
• Battery voltage at least 11.5 V
• Ignition switched on
Checking
The glow plug system is monitored by the engine control unit's
self-diagnosis system.
The necessary checks are performed with Guided fault finding.
Removing glow plugs
– Remove glow plugs using U/J extension and socket - 3220- .
1. Glow plug system 281

Installing glow plugs n AG. Volkswagen AG do

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– Install glow plugs using by V jointed extension and sockett g-u3220-
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Specified torque: ir se15 Nm
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1.2 ss Characteristics of ceramic glow plugs
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WARNING
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The ceramic glow plugs ⇒ page 282 are sensitive to jolts and
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bending. For this reason a glow plug which has dropped from
h re
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a small height (approx. 2 cm) must not be used. Even if no
spec
damage is apparent. It is absolutely necessary to follow the

installation instructions, otherwise the heater pin of the glow
t to the co
plug can break and cause engine damage.
rrectne
Visual features of ceramic glow plugs
s
Vehicles with 2 valves per cylinder head
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-A- = Metal glow plug, colour-coded -arrow-.
form
mer
-B- = Ceramic glow plug with support tube -arrow-, not colour-
atio
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coded.
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Vehicles with 4 valves per cylinder head

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-C- = Metal glow plug, colour-coded -arrow-.

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-D- = Ceramic glow plug with support tube -arrow-, not colour-
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Remove, install or check ceramic glow plugs ⇒ page 282 .
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1.3 Removing, installing and checking ceramic glow plugs
282 Rep. gr.28 - Glow plug system


equipment required
♦ Jointed spanner - 3220-
♦ Torque wrench (5... 50 Nm)
- V.A.G 1331-
♦ Hand-held multimeter -
V.A.G 1526 A-
♦ Auxiliary measuring set -
V.A.G 1594 C-
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Test prerequisites C py
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• Engine is cold
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• Ignition switched off
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Procedure
Note
Do not cant ceramic glow plugs when removing and installing.

Remove any components hindering assembly.
– Pull connectors off ceramic glow plugs.

– Remove ceramic glow plugs using U/J extension and socket,
10 mm - 3220- .
note the following:
– Before installing the drilling in cylinder head and the threads
must completely cleaned of all deposits.

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Do not oil or grease threaduthof cylinder head bore or of ceramic
or eo
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– Screw ceramic glow plugs into cylinder head by hand using U/
an
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J extension and socket, 10 mm - 3220- .
rm
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– Then tighten the ceramic glow plugs. Specified torque: 15 Nm
ot
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WARNING
spec
es, in part or in w
t to the co
♦ After installing and before the engine is started, perform a
resistance test on all ceramic glow plugs when engine is
cold.
rrectness of i
♦ If the defective ceramic glow plug is broken, remove all
l purpos
fragments from the engine, otherwise these can cause

damage to the engine.
nform
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♦ Specification: max. 1 Ω
com
tion in
r
– If the specification is exceeded, renew the defective ceramic

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1.4 Removing and installing engine speed
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sender - G28-
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♦ Hexagon key extension, 4 mm - T10370-
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♦ Or commercially available ball-ended hexagon key socket, 5

mm
Note
Two different bolts are installed, check which tool is to be used.

tion .
– Clamp off coolant hoses at engine oil cooler using hose clip
and pull off hoses.
– Remove oil filter bracket.
284 Rep. gr.28 - Glow plug system

– Remove securing bolt -arrow- and pull out engine speed send‐
er - G28- .
Installation is performed in the reverse order, observing the fol‐
lowing: specified torque for engine speed sender - G28- securing
bolt: 5 Nm.
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Service

Golf Plus 2005 ➤

4-cylinder diesel engine (1.9 l engine)

Edition 12.2013 rrectness of i

Service Department. Technical Information

28 - Glow plug system

All rights reserved.

Copyright © 2015 Volkswagen AG, Wolfsburg D3E801CBF41

10 - Removing and installing

1.5 Notes on installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

1.6 Assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

1 Dismantling and assembling engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

1.3 Removing and installing engine support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

2 Removing and installing sealing flange and flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

2.2 Removing and installing dual-mass flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

2.3 Renewing crankshaft oil seal - pulley end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

2.4 Removing and installing sealing flange - pulley end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

2.5 Renewing crankshaft sealing flange - flywheel end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

3.1 Assembly overview - crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

15 - Cylinder head, valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

2.3 Renewing valve stem seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

1.11 Checking engine oil cooler for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142

20 - Fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144

1 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144

1.1 Safety precautions when working on fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . 144

2 Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145

3 Parts of fuel supply system (Golf, Golf Plus) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146

3.2 Fuel tank, vehicles with four-wheel drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149

3.3 Emptying fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156

3.5 Removing and installing fuel gauge sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159

3.6 Checking fuel pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160

3.7 Assembly overview - fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.8 Removing and installing fuel cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166

4 Parts of fuel supply system (Touran) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168

4.1 Assembly overview - fuel tank with attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168

5.1 Fuel tank, vehicles with front-wheel drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184

23 - Mixture preparation - injection . . . . . . . . . . . . . . g.e.n A. G.. .Vo.lk.sw. a.ge. n.A.G.d . . . . . . . . . . . . . 236

2 Air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246

4.2 Adapting functions and components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 252

4.7 Removing and installing engine control unit (Touran) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258

4.9 Engine control unit (Passat) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .yi

28 - Glow plug system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 281

00 – Technical data AG. Volkswagen AG d

1.1 Engine number

The engine number (“code letters” and “serial number”) can be

1.2 Engine data

Edition 05.2012 Version 9.0

AVQ BJB BKC BRU BLS BXE BXF BXJ

2 Rep. gr.00 - Technical data

2.1 Safety precautions when working on

Risk of injury due to highly pressurised fuel.

glow plug system, the following must be noted:

♦ Always switch off the ignition before connecting or discon‐

necting electrical wiring of the injection and glow plug system

or connecting/disconnecting tester cables.

♦ Wash the engine only with the ignition switched off.

♦ Entries have been stored in the event memory of the engine

control unit if the engine was started after electrical connectors

♦ Observe prescribed procedures when disconnecting bat‐

tery ⇒ Electrical system; Rep. gr. 27 ; Battery; Discon‐

necting and reconnecting battery.

– Disconnect battery ⇒ Electrical system; Rep. gr. 27 ; Battery;

Disconnecting and reconnecting battery .